Chevrolet - Cavalier - Workshop Manual - 1998 - 1998

Factory Workshop Manual Make Chevrolet Model Cavalier Engine and year L4-2.2L VIN 4 (1998) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 8 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 11 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 12 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 16 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 19 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 21 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 22 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 24 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 25 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 26 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 29 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 30 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 31 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 32 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 33 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 35 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 36 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 38 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 41 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 42 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 43 Alarm Module: Service and Repair Vehicle Theft Deterrent - Component Changing Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 44 Vehicle Theft Deterrent - Controller Learning Diagram Engineers design the PASSLOCK system in order to prevent theft even if the various theft deterrent parts change. The tamper mode will engage if any of the following components change: ^ The PASSLOCK lock cylinder ^ The instrument cluster ^ The powertrain control module (PCM) If you replace any of the above components, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 49 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 50 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 62 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 63 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 64 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 70 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 71 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 72 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations > Page 77 Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 84 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 97 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 98 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 104 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 105 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 106 Electronic Brake Control Module: Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 107 Component Location Views Left hand lower I/P Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module (EBCM) (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 110 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM) (C2) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 111 Electronic Brake Control Module (EBCM) (C2) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement REMOVAL PROCEDURE 1. Remove the dash wiring harness connectors from the EBCM. 2. Remove the EBCM from the bracket. INSTALLATION PROCEDURE 1. Install the EBCM to the bracket. 2. Install the dash wiring harness connectors to the EBCM. 3. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement > Page 114 Electronic Brake Control Module: Service and Repair Electronic Brake Control Relay Replacement REMOVAL PROCEDURE 1. Remove the underhood fuse block cover. 2. Remove the electronic brake control relay from the underhood fuse block. INSTALLATION PROCEDURE 1. Install the electronic brake control relay into the underhood fuse block. 2. Install the underhood fuse block cover. 3. Perform the "Diagnostic System Check" in Antilock Brake System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAY Component Location Views The Cooling Fan Relay is located in the Underhood Fuse/Relay Center. The Underhood Fuse/Relay Center is located in the LH front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Control Module Assembly Bracket to Front of Dash ....................................................................................................................................25 N.m (18 lb ft) Control Module Assembly Bracket to Strut Tower .......................................................................................................................................25 N.m (18 lb ft) Control Module Assembly to Bracket ..........................................................................................................................................................10 N.m (89 lb in) Module Assembly to Mounting Bracket Nuts ............................................................................................................................................12 N.m (106 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 123 Cruise Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 124 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 125 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) Cruise Control Module: Service and Repair Cruise Control Module Replacement (LD9) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the module retaining nuts. 5. Remove the module (1) from the mounting bracket. 6. Remove the module assembly from the front of the dash. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the front of the dash. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Connect the electrical connector to the module. 3. Install the cruise control cable. 4. Adjust the cruise control cable. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) > Page 128 Cruise Control Module: Service and Repair Cruise Control Module Replacement (LN2) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the retaining nuts from the mounting studs. 5. Remove the module assembly (1) from the right strut tower. 6. Remove the module assembly from the mounting bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the mounting bracket. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Install the module assembly to strut tower. 3. Install the nuts. Tighten Tighten the nuts to 25 Nm (18 lb ft). 4. Connect the electrical connector to the module. 5. Install the cruise control cable. 6. 6. Adjust cruise control cable. 7. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C COMPRESSOR CONTROL RELAY Fuse Block Details The A/C Compressor Control Relay is located in the Engine Compartment Fuse/Relay Center. The Engine Compartment Fuse/Relay Center is located in the left front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 133 Compressor Clutch Relay: Description and Operation The A/C compressor control relay is designed to disengage the A/C compressor clutch momentarily during start-up on a warm engine. The relay is PCM controlled. Voltage is supplied from the A/C power feed circuit and the PCM completes the ground to close a set of normally opened points. This turns the compressor clutch ON. The PCM opens the ground circuit when an engine run signal is sensed with coolant temperature at a specified amount. On a warm engine start-up, a time delay of about 3 seconds allows the engine speed to stabilize before the compressor engages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation The blower speed is controlled by a knob which actuates a switch. The blower circuit is open in the OFF mode. In all other modes the blower has 4 speeds to control the amount of air that flows through the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Component Locations Audible Warning Device Control Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Component Locations > Page 142 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 145 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 146 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 147 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 148 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 149 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 150 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 159 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 160 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 161 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 163 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 164 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 166 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 167 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 169 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 170 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 174 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 177 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 178 Audible Warning Device Control Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Remove the left sound insulator. 3. Remove the retaining nuts (4) from the alarm module (5). 4. Remove the multifunction alarm assembly (5) from the convenience center. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly (5) to the convenience center. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts (4) to the alarm module (5). Tighten Tighten the nuts to 6 N-m (53 lb in). 3. Install the left sound insulator. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations DAYTIME RUNNING LAMP RELAY Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 183 Component Location Views The Daytime Running Lamp Relay is located in the Left Fuse block. The Left Fuse Block is located behind lower LH side of Instrument Panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 188 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 189 Fog/Driving Lamp Relay: Diagrams Fog Lamp Cutoff Relay Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations Horn Relay: Component Locations HORN RELAY Convenience Center The Horn Relay is located in the Convenience Center. The Convenience Center is located at the right front of the passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations > Page 194 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 201 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 212 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 213 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 214 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 215 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 216 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 222 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 227 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 228 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 229 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 230 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 231 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 241 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 246 Powertrain Control Module: Specifications PCM Retainer Bolts 6-9 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 247 Powertrain Control Module: Locations Location View At the right front corner, behind the fascia Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 250 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 251 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Powertrain Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 258 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 260 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 261 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 263 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 264 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 265 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 268 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 271 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 274 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 275 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Powertrain Control Module: Connector Views Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 285 Powertrain Control Module: Description and Operation Description The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control Control Module Function The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure Powertrain Control Module: Service and Repair Password Learn Procedure In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the PC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 288 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) Replacement/Programming Repair Instructions NOTICE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. REMOVAL PROCEDURE IMPORTANT: Turn the ignition switch OFF to prevent internal PCM damage when disconnecting or reconnecting power to the PCM (for example, battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). The ignition switch should be OFF for at least 10 seconds before disconnecting the power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and the horn. NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 5. Disconnect the PCM electrical connectors (1). 6. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 289 7. Slide the PCM and the retainer (1) from the PCM bracket (2). 8. Remove the retainer (1) from the PCM (2). INSTALLATION PROCEDURE Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the malfunctioning PCM. 1. Slide the PCM (2) into the PCM retainer (1). 2. Slide the PCM and the retainer (1) into the PCM bracket (2) slots. 3. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb ft). NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 4. Connect the PCM electrical connectors (1). 5. Install the horn and the horn attaching bolt. 6. Connect the horn electrical connector. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. 9. Reprogram the PCM and perform the Crankshaft Position System Variation Learning Procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Knock Sensor Module > Component Information > Description and Operation Knock Sensor Module: Description and Operation The KS module is an integral part of the PCM. The KS module is not serviceable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 298 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 299 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 306 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 308 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 309 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 310 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 311 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 312 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 313 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 319 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 320 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 322 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 323 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 329 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL PROCEDURE 1. Remove the relay center cover. 2. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Cover Bolts 16 ft.lb Screws 35 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 334 Ignition Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 335 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 336 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 Ignition Control Module (C1) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 > Page 339 Ignition Control Module (C2) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 340 Ignition Control Module: Description and Operation This system uses the same circuits between the ICM and the PCM that distributor type systems use. Following is a brief description for each of the IC circuits. Crankshaft Position (CKP) Sensor Activity (7X reference) - The CKP sensor generates a signal to the ICM which results in a reference pulse (square wave signal) being sent to the PCM. The PCM uses this signal to calculate crankshaft position, engine speed and injector pulse width. The engine will not start or run if this circuit is open or grounded. Reference Low - This wire is grounded through the ICM and insures that the ground circuit has no voltage drop between the ICM and the PCM which could affect performance. The PCM compares voltage pulses on the 7X or reference input to those on this circuit, ignoring any pulses that appear on both. A pulse that appears on the reference low circuit alone is assumed to be caused by Radio Frequency Interference (RFI). Ignition Control (IC) 1 & 2 - The PCM sends the ignition control pulse to the ICM on these circuits. These signals are similar to the 7X reference pulse square wave except that the PCM uses sensor inputs to determine the pulse timing to control spark advance. When the PCM receives the 7X signal, it will determine which pair of cylinders will be fired (1 & 4 or 2 & 3). It then tells the ICM which cylinder to fire through the ignition control circuits. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 341 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the ignition coils from the module (1). 4. Remove the module from the assembly plate. INSTALLATION PROCEDURE 1. Install the module to the assembly plate 2. Install the ignition coils. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Sensing and Diagnostic Module Sensing and Diagnostic Module Mounting Fasteners 14 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 348 Air Bag Control Module: Locations Sensing and Diagnostic Module (SDM) Component Location Views At the right passenger compartment, under the right seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 349 Air Bag Control Module: Diagrams Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 350 Air Bag Control Module: Description and Operation The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a Diagnostic Trouble Code (DTC). ^ Malfunction Diagnosis - The SDM displays SIR Diagnostic Trouble Codes and system status information through the use of a scan tool. ^ Driver Notification - The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. If this connector is removed from the SDM, the UART data link is broken and the Instrument Panel Cluster (IPC) will turn the AIR BAG warning lamp ON steady whenever the ignition switch is in the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury, Before attempting these procedures, the SIR system must be disabled. Refer to Disabling SIR System. With the ignition OFF inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 353 Air Bag Control Module: Service and Repair Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. Refer to Driver Or Passenger Front Seat in Seats and Carpet. 3. Remove the passenger front carpet retainer, then roll back the carpet. Refer to Floor Carpet Retainer in Seats and Carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint Sensing and Diagnostic Module (SDM) harness connector. Description 5. Disconnect the SDM harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 354 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). IMPORTANT: If the SDM mounting holes or fasteners are damaged to the extent that the module can no longer be properly mounted use the following repair. Torque the replacement fastener with a hand tool in order to prevent stripping the replacement fastener. 1. Remove the stripped fastener and discard it. 2. Drill and tap the weld nut for use with a 7.00 x 1.0 mm bolt. NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 3. Install the SDM with new fastener GM P/N 25601790. 4. Tighten Tighten fastener to 14 N.m (124 lb. in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 355 Air Bag Control Module: Service and Repair Installation Procedure 1. Install the SDM (1) to the floor pan (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the SDM mounting fasteners (2). Tighten Tighten fasteners to 14 N.m (124 lb. in). Description 3. Install the SDM harness connector to the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 356 4. Install the Connector Position Assurance (CPA) to the SDM harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Specifications Wiper Control Module: Specifications Wiper Drive System Module to Vehicle Screws ..........................................................................................................................................10 N.m (88 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions Lock Cylinder Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 367 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 368 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Lock Cylinder Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 375 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 377 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 378 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 380 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 381 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 382 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 384 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 388 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 390 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 391 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 392 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 393 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 397 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 398 Lock Cylinder Switch: Connector Views Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 400 Passlock TM Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 401 Theft Deterrent System Schematics: Passlock Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch Bypass Switch (Folding Top) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch > Page 408 Folding Top Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications At the left front luggage compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 412 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch Power Door Lock Switch: Diagrams Left Front Door Lock Switch LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 415 LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 416 RF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 417 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power door lock switch. 2. Disconnect the wire harness (8) from the power door lock switch (9). 3. Remove the power door lock switch. INSTALLATION PROCEDURE 1. Connect the wire harness (8) to the power door lock switch. 2. Install the power door lock switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Component Locations > Page 422 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Switch Location Left hand rear of engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 431 Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Indicator, ABS Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 432 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 433 Brake Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 434 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector from the fluid level switch (1). 2. Disconnect the fluid level switch using needle nose pliers in order to compress the switch locking tabs (1) at the inboard side of the master cylinder. INSTALLATION PROCEDURE 1. Connect the fluid level switch into the master cylinder reservoir until the locking tabs (3) snap into place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 435 2. Connect the electrical connector to the fluid level switch (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Technical Service Bulletins > Twist-Lock Style Brake Switches - Proper Adjustment Braking Sensor/Switch: Technical Service Bulletins Twist-Lock Style Brake Switches - Proper Adjustment File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-12 Date: April, 1998 INFORMATION Subject: Proper Adjustment of New Twist-Lock Style Brake Switches Models: 1996-98 Buick LeSabre, Park Avenue, Riviera 1996-98 Cadillac DeVille, Eldorado, Seville 1997-98 Chevrolet Malibu 1998 Chevrolet Cavalier 1996 Oldsmobile Ninety Eight 1996-98 Oldsmobile Aurora, Eighty Eight, LSS, Regency 1997-98 Oldsmobile Cutlass 1999 Oldsmobile Alero 1996-98 Pontiac Bonneville 1998 Pontiac Sunfire 1999 Pontiac Grand Am This bulletin is being issued to advise that new style brake switches were used beginning in the 1996 model year. The two switches control the brake lights, cruise control engage/release, TCC lock-up/release and the Brake/Transmission Inter-Lock function. The switches are adjusted by twisting rather than ratcheting. Using the old adjustment method of pulling up on the brake pedal can break the switch. A mis-adjusted or damaged switch may cause customer comments such as: ^ Brake lights stay on, draining the battery ^ Cruise control inoperative ^ Higher than normal fuel consumption if TCC cannot engage ^ Brake drag ^ Cruise control takes excess pedal travel to release The adjustment procedure in the Service Manual should be followed. Procedure 1. Insert the stop lamp switch into the retainer until the switch bottoms out against the brake pedal, and the switch actuator is fully depressed. 2. Turn the brake switch in the retainer clockwise until the travel stop has been reached. At this point it will be locked. Important: If the switch is not fully locked into position, a clicking noise may result. 3. The brake switch plunger should extend outward 0.5 mm to 1.5 mm (0.02 in. to 0.06 in.) if adjusted correctly. 4. If the distance the plunger extends is too great, the brake switch must be turned counter-clockwise about 45° and set to the correct distance before locking it in place by turning it clockwise until the travel stop is reached. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations At the left center of the console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 447 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component Location Views At the center console on the gear selector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 451 Enhanced Traction Control System Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Retaining Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor Wheel Speed Sensor: Locations Wheel Speed Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 457 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 458 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF LF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 461 RF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 462 LR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 463 RR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Disconnect the front wheel speed sensor electrical connector. 3. Remove the retaining bolt. 4. Remove the front wheel speed sensor. If the sensor will not slide out of the knuckle, remove the brake rotor and use a blunt punch or equivalent tool to push the sensor from the back side of the knuckle. IMPORTANT: If the sensor locating pin breaks off and remains in the knuckle during removal, proceed as follows: 1. Remove the brake rotor and remove broken pin using a blunt punch. 2. Clean the hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALLATION PROCEDURE 1. Install the front wheel speed sensor to the steering knuckle. 2. Install the retaining bolt. ^ Tighten the Torx screws to 12 Nm (107 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Connect the front wheel speed sensor electrical connector. 4. Lower the vehicle. 5. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 466 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) IMPORTANT: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Rear Suspension in Suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 467 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Remove the connector from the front wheel speed sensor. 3. Remove the harness attaching clips (2) from the control arm (3) and the splash shield (1). 4. Lower the vehicle. 5. Remove the harness attaching clips from the strut tower. 6. Cut the wheel speed sensor wiring circuits within the main engine harness. 7. Strip the insulation on the engine harness leads and the new wheel speed sensor harness leads. INSTALLATION PROCEDURE 1. Splice the sleeve provided in the jumper harness kit over each engine harness lead. 2. Install the new wheel speed sensor harness leads to the engine harness leads and crimp the connections. Make sure the wire colors match. 3. Heat shrink the tube lightly to seal the connection. 4. Install the harness attaching clip to the strut tower. 5. Raise and support the vehicle. Refer to Vehicle Lifting And Jacking. 6. Install the harness attaching clips (2) to the control arm (3) and the splash shield (1). 7. Install the connector to the front wheel speed sensor. 8. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 9. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 468 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement (Rear Axle) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting and Jacking. 2. Disconnect the two rear wheel speed sensor electrical connectors (3) from the rear wheel bearing and speed sensor assemblies (2). 3. Disconnect the rear axle harness electrical connector from the body to ABS and fuel sender connector. 4. Remove the rear axle harness retainers (1). 5. Remove the rear axle harness from the vehicle. INSTALLATION PROCEDURE 1. Install the rear axle harness to the vehicle. 2. Install the rear axle harness retainers (1). 3. Connect the rear axle harness electrical connector to the body to ABS and fuel sender connector. 4. Connect the two rear wheel speed sensor electrical connectors (3) to the rear wheel bearing and speed sensor assemblies (2). 5. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 6. Perform the Diagnostic System Check. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 473 Engine Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 479 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 480 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 481 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 484 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 485 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 491 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 492 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 494 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 495 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 497 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 498 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 499 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 501 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 503 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 505 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 506 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 507 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 508 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 509 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 510 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 511 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 512 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 513 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 517 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 518 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Brake Switch And Cruise Control Brake Switch At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 523 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 524 Brake Switch (Cruise Control): Adjustments IMPORTANT: If you do not adjust the switches properly, the cruise control system may not work properly. You may not adjust the release switch assembly and the stoplamp switch assembly until after you assemble the brake booster pushrod to the brake pedal assembly. Adjust the cruise control release switch and the stoplamp switch together. 1. Press the brake pedal assembly. Insert the switch assembly and stoplamp switch assembly into the retainers until fully seated. 2. Slowly release the brake pedal assembly back to its fully retracted position. The release switch assembly will move within its retainers to the "adjusted" position. Use the following brake pedal assembly travel distances to check for properly adjusted release and stoplamp switch assemblies: ^ Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 in) brake pedal assembly travel. Take the measurement at the centerline of the brake pedal assembly pad. ^ Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 in) after the cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 525 Brake Switch (Cruise Control): Service and Repair REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connector(s). 3. Pull the switch rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket (from the forward side). 2. With the brake or clutch pedal depressed, insert the switch into the retainer until the switch seats on the retainer. You may hear audible "clicks" as the ribbed portion of the switch pushes forward through the retainer. 3. Connect the wiring harness connector(s). 4. Adjust the switch in the following manner: 4.1. Pull the brake or clutch pedal fully rearward against the pedal stop until you can not hear audible "clicks". The switch moves in the retainer. This movement provides adjustment. 4.2. Release the brake or the clutch pedal. Repeat the above in order to ensure that you have properly adjusted the switch. 5. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations Cruise Control Clutch And Clutch Pedal Switches At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 529 Cruise Control Clutch Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly Cruise Control Switch: Service and Repair Cruise Control Switch Assembly REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connectors. 3. Pull the clutch pedal switch (1) rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket from the forward side. 2. Depress the clutch pedal (3). 3. Insert the switch into the retainer until the switch seats on the retainer. 4. Connect the wiring harness to the clutch pedal switch. 5. Use the following steps in order to adjust the switch: 5.1. Pull the clutch pedal fully rearward against the pedal stop until you cannot hear the clicks. 5.2. Move the switch in the retainer in order to adjust the switch. 5.3. Release the clutch pedal. 5.4. Repeat the procedure, if necessary, in order to properly adjust the switch. 6. Connect the wiring harness connectors. 7. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly > Page 534 Cruise Control Switch: Service and Repair Headlamp/Turn Signal/Cruise Control/Hazard Switch REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 539 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 540 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 544 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. Instrument Panel trim plate. Refer to Trim Plate in instrument Panel, Gauges and Console. 3. Control assembly screws and pull control assembly away from the instrument Panel. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. Tighten ^ Screws fully driven, seated and not stripped. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. Tighten ^ Screws to 2 N.m (18 lb in). 5. Instrument Panel trim plate. 6. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Sensor Torque Specification A/C Pressure Sensor Torque Specification A/C Pressure Sensor Fitting 44 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 552 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 553 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 554 Refrigerant Pressure Sensor / Switch: Description and Operation An electronic A/C pressure sensor is mounted in the line (between the compressor and the condenser). Its output to the PCM is variable and is dependent upon pressure inside the line. A higher pressure results in a higher voltage output. The PCM constantly monitors A/C system pressure to: 1. Disengage the A/C clutch if the pressures are too high. 2. Disengage the A/C clutch if pressures are too low. 3. Boost idle air control to compensate for A/C load at idle. 4. Control cooling fan operation. The pressure sensor is not repairable, if it fails, it must be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cutout functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. Tighten ^ Sensor to 5 Nm (44 lb in). 3. Electrical connection at the sensor. 4. Negative battery cable. Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 557 Refrigerant Pressure Sensor / Switch: Service and Repair Control Switches Conventional Mounted Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 558 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Direct Mounted Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 559 Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 560 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations Dimmer Switch: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 568 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 569 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 570 Dimmer Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 571 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 572 Dimmer Switch: Diagrams Panel Dimmer Switch Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 573 Dimmer Switch: Testing and Inspection For electrical diagnosis of the column mounted dimmer switch system, refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 578 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 579 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 580 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 581 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 582 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 583 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 584 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 585 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 586 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 591 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 592 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 593 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 594 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 595 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 596 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection For diagnosis of the system, Refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 604 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 609 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 610 Backup Lamp Switch (Manual) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Switch And Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 619 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 620 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 621 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Brake Light Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 623 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 624 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 626 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 627 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 628 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 629 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 630 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 631 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 636 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 637 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 638 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 639 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 640 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 641 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 642 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 643 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 646 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Brake Light Switch: Connector Views Brake Switch (C1) Brake Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Turn/Hazard/Front Marker/Front Park Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 649 Brake Light Switch: Adjustments REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling the switch towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. 3. For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. 4. Turn the switch 90 degrees clockwise in order to lock into position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 650 5. Install the electrical connection. 6. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 651 Brake Light Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 652 ^ For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. ^ For adjustment of the stop lamp, refer to Stop Lamp Adjustment. 3. Turn the switch 90 degrees clockwise in order to lock into position. 4. Install the electrical connection. 5. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Dome Lamp Override Switch Replacement REMOVAL PROCEDURE 1. Remove the headlining trim finish panel. 2. Remove the reading lamp switch tabs from the dome lamp housing. 3. Remove the reading lamp. INSTALLATION PROCEDURE 1. Install the reading lamp switch to the dome lamp housing. 2. Install the headlining trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 660 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 661 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 662 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 663 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 664 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 665 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 666 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 667 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 668 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 672 Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the left side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 676 Hazard Warning Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 677 Turn/Hazard Headlamp Switch (C2) Turn/Hazard Headlamp Switch (C3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 678 Hazard Warning Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > LH Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > LH > Page 686 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp Interior Light Switch: Diagrams Courtesy/Reading Lamp LH Courtesy/Reading Lamp RH Courtesy/Reading Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp > Page 689 Interior Light Switch: Diagrams Courtesy/Reading Lamp Switch LH Courtesy/Reading Lamp Switch RH Courtesy/Reading Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Turn Signal Switch Assembly ............................................................................................................................................................. 3.4 N.m (30 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 696 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 697 Turn Signal Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 698 Turn/Hazard Headlamp Switch (C3) Turn/Hazard Headlamp Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 699 Turn Signal Switch: Testing and Inspection This diagnosis covers mechanical problems only. Refer to ELECTRICAL DIAGNOSIS for turn signal switch electrical diagnosis. TURN SIGNAL WILL NOT STAY IN TURN POSITION Inspect ^ Damaged turn signal switch. TURN SIGNAL WILL NOT CANCEL Inspect ^ Loose turn signal switch mounting screws. ^ Broken turn signal switch. ^ Damaged canceling cam. TURN SIGNAL DIFFICULT TO OPERATE Inspect ^ Damaged turn signal switch. ^ Loose turn signal switch mounting screws. TURN SIGNAL WILL NOT INDICATE LANE CHANGE Inspect ^ Damaged turn signal switch. ^ Pinched turn switch wires. ^ Burned out turn indicator panel lights. HAZARD SWITCH CANNOT BE TURNED OFF Inspect ^ Damaged turn signal switch. HAZARD SWITCH WILL NOT STAY ON OR DIFFICULT TO TURN OFF Inspect ^ Loose turn signal switch. ^ Hazard switch interference with other components. ^ Foreign material interference to hazard slider lever. ^ Damaged turn signal switch. ^ Misaligned column covers. NO TURN SIGNAL LIGHTS Inspect ^ Damaged turn signal bulbs. ^ Electrical short in wiring harness. ^ Inoperative turn signal flasher. ^ Loose turn signal switch connector. ^ Damaged turn signal switch. TURN INDICATOR LIGHTS ON, BUT NOT FLASHING Inspect ^ Bulb burnt out, either in front or back or side of vehicle. ^ Inoperative turn signal flasher. ^ Inoperative turn signal switch. TURN INDICATOR LIGHTS OFF AND NOT FLASHING Inspect ^ Damaged turn signal switch. ^ Burned-out or damaged turn signal bulb. ^ High resistance connection to ground at bulb socket. ^ Loose turn signal switch connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 700 ^ Faulty turn signal flasher. NO TURN INDICATOR PANEL LIGHTS Inspect ^ Burned out bulbs or opens, grounds in the wiring harness from the front turn signal bulb socket to the indicator lights. TURN SIGNAL LIGHTS FLASH VERY RAPIDLY OR VERY SLOWLY Inspect ^ Burned out or damaged turn signal bulbs. ^ Loose turn signal connection. ^ Faulty turn signal flasher. ^ Pinched or grounded wiring harness. HAZARD SIGNAL LIGHTS WILL NOT FLASH - TURN SIGNAL FUNCTIONS NORMALLY Inspect ^ Blown fuse. ^ Inoperative hazard warning flasher. ^ Loose turn signal switch connection. ^ Damaged turn signal switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 701 Turn Signal Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 716 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 719 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 721 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 722 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 723 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 726 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 728 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 729 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 742 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 743 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 744 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 747 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 748 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 754 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 755 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 757 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 758 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 760 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 761 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 762 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 768 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 771 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 772 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 780 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 781 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 786 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 787 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 788 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 791 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 792 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 793 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 798 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 799 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 801 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 802 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 804 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 805 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 806 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 809 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 812 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 815 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 816 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 824 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 825 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 829 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 830 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 831 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 834 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 835 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 842 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 858 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 867 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 870 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 875 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 876 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 877 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 878 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 879 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 880 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 881 Fuel Level Sensor: Description and Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gauge. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 882 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Fuel level sensor (1) to the modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill the fuel tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition to the ON position for two seconds. 7.2. Turn the ignition to the OFF position for ten seconds. 7.3. Turn the ignition to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Intake Air Temperature (IAT) Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 890 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 891 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 892 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 895 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 896 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 903 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 905 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 906 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 908 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 909 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 910 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 916 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 919 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 920 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 928 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the ECT sensor. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the IAT sensor through a resistor in the PCM and monitors the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 929 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the IAT sensor into the air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 933 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 934 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 935 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 936 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 939 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 940 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 947 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 960 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 963 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 964 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 967 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 970 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 971 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 972 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure (MAP) Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 976 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 979 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 980 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 982 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 983 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 984 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 986 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 987 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 989 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 990 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 992 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 993 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 994 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 997 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 1012 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gauge. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 1013 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the throttle body. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold (2). INSTALLATION PROCEDURE 1. Install the MAP sensor (1) to the intake manifold (2). 2. Connect the MAP sensor electrical connector. 3. Install the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1017 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 41 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor Oxygen Sensor: Locations Post Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1023 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1024 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1025 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1026 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1027 Oxygen Sensor: Locations Pre-Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1028 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 1029 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1035 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1036 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1041 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1042 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1043 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 Post Converter Heated Oxygen Sensor (HO2S 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 Oxygen Sensor: Description and Operation Oxygen Sensor 1 The Oxygen Sensor (O2S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). This voltage can be measured with a scan tool. By monitoring the voltage output of the O2S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low O2S 1 voltage = rich command - Rich mixture-high O2S 1 voltage = lean command The O2S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See the DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 > Page 1067 Oxygen Sensor: Description and Operation Rear Heated Oxygen Sensor The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 Oxygen Sensor: Service and Repair Oxygen Sensor 1 REMOVAL PROCEDURE NOTICE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail of connector could affect proper operation of the oxygen sensor. IMPORTANT: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the O2S 1. IMPORTANT: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). 1. Turn the ignition switch OFF 2. Disconnect the Oxygen Sensor 1 electrical connector. IMPORTANT: Do not use excessive force when removing the 02S sensor. 3. Carefully remove the Oxygen Sensor 1. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads to the oxygen sensor with anti-seize compound, if necessary. 2. Install the Oxygen Sensor 1. Tighten the 02S 1 41 Nm (30 lb ft). 3. Connect the Oxygen Sensor 1 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 > Page 1070 Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 REMOVAL PROCEDURE NOTICE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. IMPORTANT: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the 02S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. NOTICE: The use of excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb ft). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1074 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1075 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1111 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1112 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1113 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1122 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1123 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1129 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1130 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1131 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1132 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 1135 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1136 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1137 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1142 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1143 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1144 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 1145 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Vehicle Speed Sensor (VSS) (3T40) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1181 Vehicle Speed Sensor: Description and Operation The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Transmission for more information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1221 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1222 Fuel Pressure Sensor/Switch: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the system fuel pressure. 3. Drain fuel tank. 4. Remove the fuel tank. 5. Remove the electrical connector from the fuel tank pressure sensor. 6. Remove the fuel tank pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1226 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1227 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1263 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1264 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1265 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1270 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1271 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1272 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1285 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1286 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1308 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1309 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1313 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1314 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1315 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1318 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1319 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1320 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1321 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1322 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1323 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1324 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1351 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1354 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1363 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1364 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1365 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1366 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1401 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1402 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Front End Descriminating Sensor Front End Descriminating Sensor Mounting Fasteners 10 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor > Page 1409 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1410 Auxiliary Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1411 Impact Sensor: Description and Operation The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint Sensing and Diagnostic Module (SDM). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor Important Preliminary Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the Connector Position Assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 1414 4. Remove the inflatable restraint front end discriminating sensor mounting fasteners (2). 5. Remove the inflatable restraint front end discriminating sensor (1) from the hood latch support bracket (3). Installation Procedure 1. Install the inflatable restraint front end discriminating sensor (1) to the hood latch support bracket (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Tighten Tighten fasteners to 10 N.m (89 lb. in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 1415 4. Install the Connector Position Assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 1416 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations Seat Belt Buckle Switch: Component Locations At the left passenger compartment, under the left seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations > Page 1421 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1422 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1431 Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch ............................................................................................................................. ...........................................................4 N.m (35 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 1479 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 1480 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1489 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1490 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1496 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1497 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1498 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1499 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 1502 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1503 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1504 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1508 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 1511 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 1512 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 1513 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 1519 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 1520 Power Window Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 1521 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR Power Window Switch: Diagrams LR LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 1524 LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 1525 Power Window Switch: Diagrams Master Window Switch Master Window Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 1526 Master Window Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 1527 Power Window Switch: Diagrams RR RR Window Switch RR Window Switch (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 1528 RR Window Switch (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch Power Window Switch: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. 6. Front door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1531 INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1532 Power Window Switch: Service and Repair Upper Extension Trim Panel Replacement Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1533 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1534 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1535 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 1536 Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the right side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1541 Wiper Switch Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1542 Wiper Switch: Service and Repair REMOVE OR DISCONNECT 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Remove upper and lower steering column covers. 4. Dampener assembly. 5. Headlight switch assembly. 6. Windshield wiper switch assembly. INSTALL OR CONNECT 1. Windshield wiper switch assembly. 2. Upper and lower steering column covers. 3. Tilt lever to column (if used). 4. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1548 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1549 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1550 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1551 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1552 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1553 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1554 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1555 Alignment: Technical Service Bulletins Alignment - Latest Available Specifications File In Section: 3 - Steering/Suspension Bulletin No.: 83-31-09 Date: October, 1998 INFORMATION Subject: Alignment Specifications Models: 1998-99 Passenger Cars and Trucks This bulletin is being issued to communicate, in chart form, the final 1998 and the initial 1999 model year vehicle alignment specifications. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1556 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1557 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1558 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1559 Specifications noted in these charts are the latest available and supersede any that have been previously published. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications Alignment: Specifications Vehicle Ride (Trim) Height Specifications J And K Measurements Model: 2JB37/2JB69 Suspension: FE1/FE2 Tire Size: P/195/70R14 Z: 12 mm (15/32 in) J: 233 mm (9.17 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 1562 K: 240 mm (9.45 in) Model: 2JB37/2JB69 Suspension: FE1/FE2 Tire Size: P/195/65R15 Z: 6 mm (16/64 in) J: 233 mm (9.17 in) K: 240 mm (9.45 in) Model: 2JB67 Suspension: FE1/FE2 Tire Size: P/195/65R15 Z: 6 mm (16/64 in) J: 233 mm (9.17 in) K: 240 mm (9.45 in) All measurements taken with a full fuel tank. Measurements for J, K, and Z all have +/- 10 mm (3/8 in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 1563 Alignment: Specifications Alignment Specifications Wheel Alignment Specifications Front Caster: Alignment Specification ....................................................................................................................... ............................................................... 1.45° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Front Camber: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Individual Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.12° Sum Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.25° Cross Camber: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Cross Caster: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Rear Camber: Alignment Specification ....................................................................................................................... .............................................................. -0.40° Tolerance ................................................................... ....................................................................................................................................... ± 0.75° Rear Sum Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.20° Tolerance ................................................................... ....................................................................................................................................... ± 0.30° Rear Thrust Angle: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.25° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, the control arms, the suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and no other loading or items in the trunk or passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1566 Alignment: Description and Operation Caster Description The caster is the tilting of the front steering axis (at the top) (1) either forward or backward from the vertical. A backward tilt is positive (+) and a forward tilt is negative (-). The caster influences directional control of the steering but does not affect the tire wear. The caster is affected by vehicle height, therefore it is important to keep the body at the designed height. Overloading the vehicle, or a weak or sagging rear spring, will affect the caster. When the rear of the vehicle is lower than the designed trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than the designated trim height, the front suspension moves to a less positive caster. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1567 Alignment: Description and Operation Camber Description The camber is the tilting of the front wheels from the vertical (1) when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. The camber setting will influence the directional control and the tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1568 Alignment: Description and Operation Toe Description The toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, the toe is positive (+). When the wheels are turned out, the toe is negative (-). The actual amount of toe is nominally only a fraction of a degree. The purpose of the toe is to ensure that the wheels roll parallel. The toe also serves to offset the small deflections of the wheel support system that occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, the wheels tend to roll parallel on the road when the vehicle is moving. The toe affects tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1569 Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, the control arms, the suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and no other loading or items in the trunk or passenger compartment. Caster Description The caster is the tilting of the front steering axis (at the top) (1) either forward or backward from the vertical. A backward tilt is positive (+) and a forward tilt is negative (-). The caster influences directional control of the steering but does not affect the tire wear. The caster is affected by vehicle height, therefore it is important to keep the body at the designed height. Overloading the vehicle, or a weak or sagging rear spring, will affect the caster. When the rear of the vehicle is lower than the designed trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than the designated trim height, the front suspension moves to a less positive caster. Camber Description The camber is the tilting of the front wheels from the vertical (1) when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. The camber setting will influence the directional control and the tire wear. Toe Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1570 The toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, the toe is positive (+). When the wheels are turned out, the toe is negative (-). The actual amount of toe is nominally only a fraction of a degree. The purpose of the toe is to ensure that the wheels roll parallel. The toe also serves to offset the small deflections of the wheel support system that occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, the wheels tend to roll parallel on the road when the vehicle is moving. The toe affects tire wear. Thrust Angles Description The front wheels aim or steer the vehicle, but the rear wheels control the tracking. This tracking action is relative to thrust angle. Thrust angle (2) is defined as the path that the rear wheels will take. Ideally, the thrust angle is geometrically aligned with the body centerline (1). Lead/Pull Description Lead/Pull is the deviation of the vehicle from a straight path, on a level road with no pressure on the steering wheel. Lead/Pull is generally caused by the following conditions: ^ A misconstructed tire. ^ An uneven brake adjustment. ^ A misaligned wheel. The way in which a tire is built can produce lead in a vehicle. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The RADIAL TIRE LEAD/PULL CORRECTION chart should be used to make sure that the front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead. Torque Steer Description Some degree of torque steer to the right may normally be experienced during a heavy throttle application on some front wheel drive vehicles which do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and an associated difference in an axle angle. Vehicles with intermediate shaft assembly have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Description > Page 1571 ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front for a difference in brand, construction or size. If the tires appear similar, change the front tires side to side and re-set the vehicle. Tire and wheel assemblies have the most significant effect on the torque steer correction. ^ A large difference in the right and left front tire pressure. ^ Any looseness in the control arm bushings, the tie rod assemblies, or the steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead deceleration. ^ A high front trim height which would increase the drive angle axle. ^ A binding or tight drive axle joint. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (15 and 30 mph). ^ An incorrect, worn or loose engine mounts causes adverse drive axle angles. ^ An unequal engine/transmission height from the left side to the right side of the vehicle. Determine the measuring points. Replace the engine/transmission mount if the difference from side to side is more than 6 mm (17/64 in). Do not shim the engine mounts. This may cause other symptoms. ^ On occasion, the side to side trim height differences may be the result of an inoperative stabilizer shaft. Disconnect the stabilizer links. Measure the trim heights again after the vehicle has been settled, driven a short distance. Replace the stabilizer shaft, if the side to side difference is corrected. Do not change the stabilizer shaft however, if there is no change in the trim height. A trim height difference of more than 6 mm (17/64 in), indicates a bent stabilizer shaft, attaching links or a suspension component that may need replacement. The following conditions affect the vehicle handling and/or a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ An incorrect front-wheel alignment or a rear-wheel alignment condition would cause the vehicle to track incorrectly. A difference in the front wheel to the rear wheel measurement. compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or other condition. The front-wheel caster should be equal or within specifications and the camber may be biased slightly in-order to offset a lead condition. ^ Suspension support misalignment. Refer to BODY AND FRAME for measurement points in order to determine proper underbody alignment. Front steering damage such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering Alignment: Testing and Inspection Hard Steering Hard Steering - Part 1 Of 2 Hard Steering - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1574 Alignment: Testing and Inspection Memory Steer Memory Steer - Part 1 Of 2 Memory Steer - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1575 Alignment: Testing and Inspection Torque Steer Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and the associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required in order to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: ^ A large difference in the right and the left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front tires for a difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. The tire and the wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joints. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (14 and 30 mph) ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal engine/transmission height from the left side to the right side of the vehicle. If a difference from side to side is more than 6 mm (17/64 in) , change the trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified Z heights. Replace the mounts. Do not shim the engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. In order to check this, disconnect the stabilizer links and re-measure the trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in the trim height, do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 in), indicates a possible bent stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect the vehicle handling and/or effect a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to track incorrectly. A difference in the front wheel to rear wheel measurement compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or an other condition. Front-wheel caster should be equal or within the specifications and the camber may be biased slightly in order to offset a lead condition. ^ Suspension support misalignment. Refer to UNDERBODY, which lists measurement points in order to determine proper underbody alignment. ^ Front suspension damage, such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1576 Vehicle Leads/Pulls Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1577 Alignment: Testing and Inspection Hard Steering - Part 1 Of 2 Hard Steering - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1578 Memory Steer - Part 1 Of 2 Memory Steer - Part 2 Of 2 Torque Steer Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and the associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required in order to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: ^ A large difference in the right and the left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front tires for a difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. The tire and the wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joints. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (14 and 30 mph) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1579 ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal engine/transmission height from the left side to the right side of the vehicle. If a difference from side to side is more than 6 mm (17/64 in) , change the trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified Z heights. Replace the mounts. Do not shim the engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. In order to check this, disconnect the stabilizer links and re-measure the trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in the trim height, do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 in), indicates a possible bent stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect the vehicle handling and/or effect a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to track incorrectly. A difference in the front wheel to rear wheel measurement compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or an other condition. Front-wheel caster should be equal or within the specifications and the camber may be biased slightly in order to offset a lead condition. ^ Suspension support misalignment. Refer to UNDERBODY, which lists measurement points in order to determine proper underbody alignment. ^ Front suspension damage, such as a bent strut. Vehicle Leads/Pulls Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1580 Wander Or Poor Steering Stability Dog Tracking Body Leans Or Sways In Corners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1581 Suspension Bottoms Noisy Front Suspension Abnormal Or Excessive Tire Wear - Part 1 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > System Diagnosis > Hard Steering > Page 1582 Abnormal Or Excessive Tire Wear - Part 2 Of 2 Wheel Bearings Diagnosis Wheel Bearings Diagnosis CAUTION: front wheel drive vehicles, drive wheel spin should be limited to 35 mph as indicated on the speedometer. This limit is necessary because the speedometer only Indicates one-half of the actual wheel speed when one drive wheel is spinning and the other drive wheel Is stopped. Unless care is taken In limiting drive wheel spin, the spinning wheel can reach excessive speeds. This can result in possible tire disintegration or differential failure, which could cause serious personal injury or extensive vehicle damage. Wheel Tramp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection Alignment: Service and Repair Preliminary Inspection PRELIMINARY INSPECTIONS The steering and the ride complaints are not always the result of improper alignment. Another possibility is tire lead due to worn or improperly manufactured tires. The lead is the vehicle's deviation from a straight path on a level road without pressure on the steering wheel. Refer to VEHICLE LEADS/PULLS in SUSPENSION GENERAL DIAGNOSIS for the procedure to determine if the vehicle had a lead problem. Before making any adjustment affecting wheel alignment, make the following inspections in order to ensure correct the alignment readings and the alignment adjustments. Inspect 1. Inspect all the tires for the proper inflation pressures. Also check that the tires have about the same tread wear. 2. Inspect the hub and bearing assemblies for excessive wear. Correct as necessary. 3. Inspect the ball joints and the tie rod ends; if they are loose, correct them before adjusting. 4. Inspect the vehicle trim height. If it is out of limits and a correction is to be made, do so before adjusting the alignment. Refer to TRIM HEIGHT SPECIFICATIONS in SUSPENSION GENERAL DIAGNOSIS. 5. Inspect the strut dampeners for proper operation. 6. Inspect the control arms for loose bushings. 7. Inspect the stabilizer shaft for loose or missing parts. 8. Inspect the suspension and the steering components for damage and replace the parts as necessary. Consideration must be given to excess loads, such as tool boxes, sample cases, etc. If the items are normally carried in the vehicle, the items should remain in the vehicle during alignment adjustments. Loads such as these should be centered in the vehicle whenever possible to minimize their effects. Consideration should also be given to the condition of the equipment being used in order to adjust the alignment. Be sure to follow the equipment manufacturer's instructions. Regardless of the equipment used to adjust the alignment, the vehicle must be on a level surface, both fore-and-aft and sideways. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1585 Alignment: Service and Repair Ride/Trim Height Measurement and Adjustment 1. Prior to measuring the vehicle trim height, prepare the vehicle as follows: 2. Ensure that the following conditions exist: 2.1. The fuel gage reads full. 2.2. The spare tire and the tools are properly located. 2.3. The vehicle is free of the ice, the snow and the mud accumulations. 3. Set the front and the rear tire pressure to within plus or minus 20 kPa (3 psi) of the recommended pressure shown on the tire placard. If two load conditions are shown on the placard, use the lower load condition. 4. Close the engine compartment hood and all of the doors. 5. Up to 7 kg (15.5 lb) may be left in the trunk if it is located approximately on the vehicle centerline. Remove the items necessary in order to meet this requirement. 6. Measure the vehicle trim height as follows: ^ Z and J Dimensions: Lift the front bumper of the vehicle up approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle settle. Repeat twice for a total of 3 times. Measure Z and J dimensions. Push the front bumper down approximately 38.0 mm (1 1/2 in). Gently repeat twice for a total of 3 times. Measure Z and J dimensions. True heights are the average of the high and low measurements. ^ K dimension: Lift the rear bumper of the vehicle up approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle settle. Repeat twice for a total of 3 times. Measure K dimension. Push the rear bumper down approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle rise on its own. Repeat twice for a total of 3 times. Measure K dimension. True heights are the average of the high Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1586 and low measurements. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1587 Alignment: Service and Repair Front Wheel Alignment Measuring Front Alignment Angles MEASURING FRONT ALIGNMENT ANGLES Important: ^ Install the alignment equipment following the manufacturer's instructions. ^ Jounce the front and rear bumpers three times to normalize the suspension prior to measuring the angles. ^ Measure the alignment angles and record the readings. If adjustments are necessary, make them in the following order: 1. Camber. 2. Toe. Front Caster Adjustment The caster is not adjustable. If the caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace the parts as necessary. Refer to BODY AND FRAME for measurement points in order to determine the proper underbody alignment. Front Camber Adjustment Important: When the camber adjustment is necessary, refer to STRUT AND KNUCKLE SCRIBING for instructions on modifying the front strut. 1. Loosen both of the strut to knuckle nuts in order to allow slight movement. 2. Adjust the camber to specification by moving the top of the wheel in or out. Refer to WHEEL ALIGNMENT SPECIFICATIONS. 3. Tighten the strut to the knuckle nuts. Tighten Tighten the strut to the knuckle nuts to 180 Nm (133 ft. lbs.). Front Toe Adjustment 1. Be sure the steering wheel is set in a straight ahead position within +/- 5°. 2. Loosen the clamp bolt (4). 3. Adjust the toe to specification by turning the adjuster (3). Tighten Tighten the jam nut to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1588 Refer to FASTENER TIGHTENING SPECIFICATIONS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1589 Alignment: Service and Repair Rear Wheel Alignment MEASURING REAR ALIGNMENT ANGLES After the front wheel alignment has been completed, the rear alignment angles should be checked if there is excessive rear tire wear or the wheels do not track properly. The rear wheels should be parallel to and the same distance from the vehicle's centerline. REAR WHEEL ALIGNMENT Rear wheel alignment is not adjustable. If the camber and toe angles are not within the specifications, inspect for underbody or rear suspension damage. Refer to BODY AND FRAME to determine proper underbody alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1595 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1596 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1597 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1598 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1599 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1600 Diagnostic Chart CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn OFF the in-tank fuel pump for 2 seconds after the ignition switch is turned ON or for 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. The unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION The number(s) below refer(s) to the step number(s) on the Diagnostic Table. 2. In order to relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gauge should be 284-325 kPa (41-47 psi). 3. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more of the following areas: ^ The fuel pump check valve ^ The fuel pump flex pipe ^ The valve or valve seat within the fuel pressure regulator ^ The fuel injector(s) 5. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or a misfire. You can use a scan tool in order to diagnose a lean condition. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. 8. When the engine is idling, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1601 the fuel pressure regulator. This will cause lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine turned OFF. 12. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition can cause a DTC P0132 or a DTC P0172 to set. Driveability conditions that are associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 13. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a malfunctioning fuel pressure regulator. 15. Fuel pressure being below 284 kPa (41 psi) can cause a lean condition. A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions that are associated with lean conditions can include hard starting (when the engine is cold), a hesitation, poor driveability, a lack of power, surging, and misfiring. 16. Restricting the fuel flow causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool in order to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gauge outlet hose is pinched. 22. Check the spark plug that is associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1617 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1623 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1629 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1630 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1631 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1637 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1638 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1639 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1640 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. Refer to Maintenance. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. Tighten the upper air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... ...................................................... 1.01 mm (.040 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 1664 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ........................................................ 18 Nm (13 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1665 Spark Plug: Application and ID AC Type ............................................................................................................................................... ....................................................................... 41-928 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1666 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition Spark Plug: Service and Repair Conventional Ignition Description Description Removal Procedure 1. Turn the ignition key OFF. 2. Remove foreign material from around the spark plug holes. 3. Remove the wires from the plugs. 4. Remove the spark plug using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2 Install new plugs and tighten properly. 3. Reapply dielectric lubricant to the insulator boot. Tighten to 18 Nm (13 lb ft). 4. Reattach the boots to the plugs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition > Page 1669 Spark Plug: Service and Repair Integrated Direct Ignition Removal Procedure Tools Required J 36011 Spark Plug Connector Assembly Removal Tool 1. Remove the negative battery cable. 2. Remove the integrated Direct Ignition (IDI) assembly 4 bolts and connector. 3. Remove by pulling straight up on the housing. 4. Use the J 36011 to remove connector assembly(s) is stuck to the spark plugs. Use the tools by first twisting then pulling up on the connector assembly. 5. Remove the debris from the area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start the spark plugs into the cylinder head and tighten. Tighten the plugs to 18 Nm (13 lb ft). 3. Reinstall onto the IDI any spark plug boot connector assembly that stuck to a spark plug. ^ Check to be sure the spring terminal is inside the boot. ^ Reapply dielectric lubricant to the insulator boot. 4. Locate the IDI assembly over the spark plugs and push straight down. 5. Remove any loose lubricant that is present on the IDI assembly to cam housing bolts. IMPORTANT: Hand start the IDI assembly to cam housing bolts. 6. Apply threadlocker onto the IDI assembly to cam housing bolts. Tighten the bolts to 22 Nm (16 lb ft). 7. Install the electrical connector. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1673 Compression Check: Testing and Inspection ENGINE COMPRESSION TEST Perform the following steps in order to conduct a compression test for VIN 4: 1. Conduct the following steps in order to check cylinder compression: 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module. 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). IMPORTANT: The results of a compression test will fall into the following categories: ^ Normal-Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings-Compression low on first stroke. Tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. ^ Valves-Compression low on first stroke. Does not tend to build up on the following strokes. Does not improve much with addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine uses hydraulic lifters and no valve lash adjustment is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1681 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1682 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1683 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1684 Drive Belt: Specifications SERPENTINE BELT Belt tension is maintained by a spring tensioned idler pulley. No adjustment of the serpentine belt is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. IMPORTANT: Do not exceed 40 Nm (30 ft. lbs.) on the tensioner center bolt. 2. Rotate the belt tensioner clockwise. Use a 15 mm wrench. 3. Slide the belt from the generator pulley. 4. Release the tensioner. 5. If the vehicle has A/C remove the drive belt from the A/C compressor pulley. 6. Remove the drive belt. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 1687 1. Route the drive belt. 2. If the vehicle has A/C route the drive belt around the A/C compressor pulley. 3. Rotate the belt tensioner clockwise. Use a 15 mm wrench. 4. Slide the belt onto the generator pulley. 5. Release the tensioner. NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 1688 Drive Belt: Service and Repair Pump Drive Belt SERPENTINE BELT Vehicles equipped with a 2.2L engine have the power steering pump driven by a serpentine belt. The serpentine belt is self-adjusting within tensioner operating limits. For on-vehicle service of the serpentine belt, refer to ENGINE. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1702 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1708 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1709 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. Refer to Maintenance. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. Tighten the upper air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - PWM Filter Removal Fluid Filter - A/T: Technical Service Bulletins A/T - PWM Filter Removal File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-016 Date: September, 2000 Subject: Removal Of The PWM Filter From The Spacer Plate - 4T40E/4T45E Automatic Transmission Models: 1998-2000 Chevrolet Cavalier, Malibu 1998-1999 Oldsmobile Cutlass 1999-2000 Oldsmobile Alero 1998-2000 Pontiac Sunfire 1999-2000 Pontiac Grand Am with 4T40E or 4T45E Automatic Transmission (RPOs MN4, MN5) The PWM filter (Item 17), which snaps into the spacer plate, has been eliminated. The use of a filter in this location is redundant. The PWM has its own filter located on the solenoid. Pictures of the spacer plate and the filter location on the spacer plate as shown. The PWM filter which was located in the spacer plate has been removed from GMSPO inventory and is no longer available. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid Filter - A/T: Service and Repair 3T40 Automatic Transaxle A/T Fluid/Filter Changing (Remove) PREPARATION ^ Tools Required J 35944-A Oil Cooler and Line Flusher - J 35944-20 Cooler Flushing Fluid Whenever you remove a transmission for service, do a transmission oil cooler flushing. It is essential to flush the oil cooler under the following conditions: ^ After a major overhaul ^ Suspected contamination ^ Pump or torque converter replacement For complete transmission service, perform the flush procedure after the overhauled or replacement assembly is installed in the vehicle. 1. Remove the fill cap on the J 35944-A. 2. Fill the can with 0.6 liter (20-21 ounces) of J 35944-20, or equivalent, cooler flushing fluid. Do not overfill. If you overfill, the tool will need recharging with air before the backflush. 3. Follow the manufacturer's suggested procedures for proper handling of the solution. IMPORTANT: Shop air supply must not exceed 825 kPa (120 psi), and must be equipped with a water/oil filter. 4. Secure the fill cap, and pressurize the flusher can with shop air to 550-700 kPa (80-100 psi). 5. Connect the J 35944-A to the transmission end of the transmission cooler pipe that feeds the bottom fitting of the oil cooler. 6. Connect the discharge hose to the top oil cooler pipe. 7. Clip the discharge hose to the oil drain container. 8. With the water valve on the tool in the OFF position, connect the water hose from the water supply to the tool. 9. Turn ON the water supply at the faucet. INITIAL FLUSHING IMPORTANT: If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 1. Switch the water valve on the tool to the ON position. Allow the water to flow through the oil cooler for 10 seconds in order to remove the transmission fluid in the system. 2. Switch the water valve on the tool to the OFF position. Clip the discharge hose onto a 5 gallon pail with a lid. If no lid is available, place a shop towel over the end of the hose in order to prevent splash. The discharge will foam vigorously when you introduce solution into the water stream. 3. Switch the water valve on the tool to the ON position. Depress the trigger that mixes the flushing solution into the water flow. Use the bale clip on the handle in order to hold down the trigger. 4. Flush the oil cooler with water and solution for 2 minutes. During the flush, attach the air supply to the air valve on the tool for 3-5 seconds after every 15-20 second interval in order to create a surging action. 5. Release the trigger. Switch the water valve on the tool to the OFF position. 6. Disconnect both hoses from the oil cooler pipes. BACKFLUSH 1. Connect the hoses to the oil cooler pipes in order to perform a backflush. 2. Switch water valve on the tool to the ON position. Depress the trigger in order to mix the flushing solution with the water flow. Use the bale clip on the handle to hold down the trigger. 3. Flush the oil cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve on the tool for 3-5 seconds after each 15-20 second interval in order to create a surging action. 4. Release the trigger. Allow water only to rinse the oil cooler for 1 minute. 5. Turn the water supply OFF at the faucet. 6. Attach the air supply to the air valve on the tool. Dry out the system with air for at least 2 minutes. Dry out the system longer than 2 minutes, if moisture from the oil cooler line discharge hose is visible. 7. Connect the cooler feed pipe to the transmission. The cooler feed is the bottom connection at the transmission. 8. If not already connected, attach the discharge hose to the cooler return pipe. Place the hose into an appropriate drain container. 9. After filling the transmission with DEXRON(R) III or DEXRON(R) IIE automatic transmission fluid, or equivalent, start the engine. Run the engine for 30 seconds. This removes any residual moisture from the oil cooler and the cooler pipes, protects all the components from corrosion, and checks the flow rate through the cooler. 10. You should get a minimum of 1.9 liters (2 quarts) of transmission fluid during this 30 second run. If the flow of fluid is insufficient, disconnect the oil cooler feed line at the radiator and restart the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1716 11. If the flow is insufficient, inspect the transmission for cause. Inspect the cooler pipes and fittings. Repeat the cooler flushing procedure. Replace the cooler if the flow is still insufficient. 12. Remove the discharge hose. 13. Reconnect the cooler return pipe to the transmission. 14. Refill the unit to the proper fluid level. A/T Fluid/Filter Changing (Install) REMOVAL PROCEDURE 1. Remove the oil level indicator. 2. Remove the nut or bolt that retains the fill tube to the mounting bracket. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a drain pan under the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1717 5. Loosen the filler tube from the transmission. 6. Remove the filler tube seal. 7. Lower the vehicle. 8. Pull the tube out of the vehicle from the top. INSTALLATION PROCEDURE 1. Install the filler tube through the top of the vehicle. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Install the filler tube seal into the transmission. Lubricate the seal with DEXRON(R) IIE, or DEXRON(R) III. 4. Install the filler tube into the transmission. 5. Lower the vehicle. 6. Install the nut that retains the tube to the mounting bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1718 7. Install the oil level indicator. 8. Adjust the oil level. A/T Fluid/Filter Changing (F/F Changing) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place A drain . pan under the transmission Oil Pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the Oil Pan sealing surfaces. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1719 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1720 4. Install a new oil pan gasket. 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1721 Fluid Filter - A/T: Service and Repair 4T40-E Automatic Transaxle Oil Filter and Seal Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Drain the transmission oil. Refer to A/T Fluid/Filter Changing. 3. Remove the oil pan attaching bolts and the oil pan. 4. Remove the gasket. 5. Remove the oil filter assembly. 6. Remove the filter neck seal from the transmission case. Use a small screwdriver. Do not to score the case during removal. Discard the filter seal, it is not reusable. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1722 1. Install the new oil filter neck seal. Tap gently and evenly on the seal in order to prevent damage to the case bore or the seal. 2. Install the new oil filter. 3. Install the oil pan gasket and the oil pan. Use a new gasket if the sealing rings are damaged. 4. Install the oil pan attaching bolts. ^ Tighten the bolts to 14 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) III oil. 7. Inspect the oil pan gasket for leaks. A/T Fluid/Filter Changing REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the oil pan sealing surfaces. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1723 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure (Diagnosis). 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1724 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1725 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation A woven plastic strainer is located on the lower end of the fuel sender. This filter prevents dirt from entering the fuel line and also stops water unless the filter becomes completely submerged in water. This filter is self cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, should this occur, the fuel tank should be removed and thoroughly cleaned and the tank filter replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1733 Fuel Pump Pickup Filter: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain the fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Note the strainer (1) position for future reference. 6. Support the reservoir with one hand and grasp the strainer with the other hand. 7. Use a screwdriver to pry the strainer ferrule off the reservoir. 8. Discard the strainer. INSTALLATION PROCEDURE 1. Install the new strainer (1) to reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition switch to the ON position for two seconds. 7.2. Turn the ignition switch OFF position for ten seconds. 7.3. Turn the ignition switch to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1738 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 17 Nm (13 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1739 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1740 Oil Filter: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan bolt. 4. Remove the oil filter. INSTALLATION PROCEDURE 1. Install the oil filter. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the oil pan drain bolt. ^ Tighten the oil pan drain bolt to 26 Nm (19 ft. lbs.). Lower the vehicle. 3. Fill the engine with oil to the appropriate mark. 4. Install negative battery cable. 5. Start engine and inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission - Whine at 2800-3200 RPM Heater Hose: Customer Interest Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission - Whine at 2800-3200 RPM Heater Hose: All Technical Service Bulletins Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1755 Heater Hose: Specifications Heater Hose and Pipe Torque Specifications Heater Hose and Pipe Torque Specifications Heater Outlet Screws 9 in.lb Heater Outlet Pipe Nut 18 ft.lb Heater Pipe Assembly to Engine Bolt and Nut 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1756 Heater Hose: Locations Heater Pipes The heater hoses are attached to the heater core at the front of dash and to the inlet and outlet pipes at the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1757 Heater Hose: Description and Operation The heater hoses and pipes carry engine coolant from the engine to the heater core. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Preliminary Instructions Heater Hose: Service and Repair Preliminary Instructions Heater Hoses Heater Pipes Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Make sure conduit and heat sleeving are in the same location as the original when replacing a hose. when servicing a heater hose with a quick connect assembly, REPLACEMENT OF THE RETAINER IS RECOMMENDED. Refer to Quick Connect Retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 1760 Heater Hose: Service and Repair Heater Hoses Heater Hoses Remove or Disconnect 1. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater hoses from heater pipes. 3. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Heater hoses to heater pipes. 3. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 1761 Heater Hose: Service and Repair Heater Pipe Assembly Heater Pipes Remove or Disconnect 1. Drain coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater core to pipe hoses from beater pipe assembly. 3. Heater pipe hose at coolant outlet on engine. 4. Heater pipe hose at coolant inlet on engine. 5. Bolt and nuts retaining pipe to engine. 6. Heater pipe assembly. Install or Connect 1. Heater pipe assembly. 2. Bolt and nuts retaining pipe to engine. Tighten ^ Bolt and nut to 25 N.m (18 lb ft). 3. Heater pipe hose to coolant inlet on engine. 4. Heater pipe hose to coolant outlet on engine. 5. Heater core to pipe hoses to heater pipe assembly. 6. Refill coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: Customer Interest A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 1770 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: All Technical Service Bulletins A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 1776 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1777 Hose/Line HVAC: Specifications A/C Accumulator Inlet Fitting 18 ft.lb A/C Accumulator Outlet Fitting 18 ft.lb A/C Accumulator Tube to Evaporator 18 ft.lb A/C Compressor and Condenser Hose Bolt to Rear of Compressor 24 ft.lb A/C Condenser Inlet From Evaporator Fitting Nut 12 ft.lb A/C Condenser Outlet Fitting Nut 12 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube > Page 1780 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube > Page 1781 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) Hose/Line HVAC: Service and Repair Accumulator Tube (Evaporator to Accumulator) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Tube at accumulator and discard O-ring seal. 3. Raise vehicle. Refer to Lifting in General Information. 4. TUBE at evaporator and discard O-ring seals. 5. Lower vehicle, remove tube. Install or Connect 1. Set tube in place. Raise vehicle. 2. TUBE at evaporator using new O-ring seals. Tighten ^ Fitting to 24 N.m (18 lb ft). 3. Lower vehicle. 4. Tube at accumulator using a new O-ring seal. Tighten ^ Fitting to 24 N.m (18 lb ft). 5. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 1784 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Switch connection on discharge line. 3. Cruise control module (if equipped). 4. Suction line (accumulator to compressor) at accumulator. 5. Upper closeout panel. 6. Connection at the condenser. 7. Raise vehicle. 8. Block fitting at the rear head of the compressor. 9. Compressor/condenser hose assembly. Important ^ Remove and discard all used O-ring seals and sealing washers. Install or Connect 1. Compressor/condenser hose assembly. 2. Block fitting to reai head of compressor using new sealing washers. Refer to Sealing Washer Installation Procedures. Tighten ^ Bolt to 33 N.m (24 lb ft). 3. Lower vehicle. 4. Suction line at the accumulator using a new O-ring seal. Tighten ^ Nut to 24 N.m (18 lb ft). 5. Connection at the condenser using new O-ring seal. Tighten ^ Nut to 24 N.m (18 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 1785 6. Switch connection on discharge line. 7. Cruise control module. 8. Upper closeout panel. 9. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 10. Check system operation and leak test. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 1786 Hose/Line HVAC: Service and Repair Evaporator Tube (Evaporator to Condenser) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Upper closeout panel. 3. Connection from the condenser and discard the O-ring seal. 4. Tube from retaining clip on the body side rail. 5. Raise vehicle. Refer to Lifting in General Information. 6. Tube from the evaporator and discard the O-ring seals. 7. Lower the vehicle and remove the evaporator tube. Install or Connect 1. Set evaporator tube in place. 2. Raise vehicle. 3. Tube to evaporator using new O-ring seals. Tighten ^ Fitting to 24 N.m (18 lb ft). 4. Lower vehicle. 5. Tube to retaining clip on the body side rail. 6. Connection at condenser using new O-ring seals. Tighten ^ Nut to 16 N.m (12 lb ft). 7. Upper closeout panel. 8. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Inlet Line Fittings ........................................................................................................................................................... 27 N.m (20 ft. lbs.) Power Steering Outlet Hose Assembly Fittings ....................................................................................................................................... 27 N.m (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Power Steering Line/Hose: Service and Repair Gear Inlet Hose Power Steering Restrictor Valve And Hose Routing Power Steering Line And Hose Routing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 1792 Power Steering Line And Hose Routing Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 1793 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. Tighten ^ Gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Refer to BLEEDING THE POWER STEERING SYSTEM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 1794 Power Steering Line/Hose: Service and Repair Gear Outlet Hose Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten ^ Outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten ^ Hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill with fluid and bleed air from power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM. Inspect ^ For leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Technical Service Bulletins > Cooling - Upper Radiator Hose Replacement Radiator Hose: Technical Service Bulletins Cooling - Upper Radiator Hose Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-015 Date: October, 1999 INFORMATION Subject: Upper Radiator Hose Replacement Models: 1998-2000 Chevrolet Cavalier 1998-2000 Pontiac Sunfire with 2.2L, L-4 Engine (VIN 4 RPO LN2) When replacing the upper radiator hose, be sure to install protective conduit, P/N 22618378. Position the conduit to protect the hose from contact (2) with the battery tray (1), 21 mm (8 1⁄4 in) with the seam of the conduit facing away from the battery tray. Parts Information Part Number Description 22618378 Conduit Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) Radiator Hose: Service and Repair Radiator Hose Replacement (Inlet) REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. It silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant to a level below the hose being removed. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the radiator inlet hose and the clamps from the radiator and the coolant outlet. 4. Disconnect the radiator outlet hose and the clamps from the following places: ^ The radiator ^ The coolant pump ^ The radiator surge tank 5. Remove the radiator outlet hose. INSTALLATION PROCEDURE NOTICE: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. 1. Install the radiator outlet hose and the clamps to the following places: ^ The radiator ^ The coolant pump ^ The radiator surge tank 2. Install the radiator inlet hose and the clamp to the radiator and the coolant outlet. NOTICE: Refer to Fastener Notice in Cautions and Notices. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1801 3. Connect the negative battery cable. ^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.). 4. Refill the coolant. Refer to Draining and Filling Cooling System. 5. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1802 Radiator Hose: Service and Repair Radiator Hose Replacement (Outlet) REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant to a level below the hose that is being removed. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the radiator inlet hose (3) and the clamps (2) from the radiator and the coolant outlet (1). 4. Disconnect the radiator outlet hose (1) and the clamps (2) from the following places: ^ The radiator ^ The radiator outlet pipe (3) ^ The radiator surge tank 5. Remove the radiator outlet hose. INSTALLATION PROCEDURE NOTICE: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1803 1. Install the radiator outlet hose (3) and the clamps (2) to the following places: ^ The radiator ^ The radiator outlet pipe (3) ^ The radiator surge tank 2. Install the radiator inlet hose (3) and the clamps (2) to the coolant outlet (1) and the radiator. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Connect the negative battery cable. ^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.). 4. Refill the coolant. Refer to Draining and Filling Cooling System. 5. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1804 Radiator Hose: Service and Repair Radiator Pipe Replacement - Outlet REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the exhaust manifold heat shield. 4. Remove the cover to the outlet pipe bolt through the exhaust manifold runners. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Disconnect the radiator outlet hose (1) from the radiator outlet pipe (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1805 7. Remove the radiator outlet pipe (1) to the oil pan (2) bolt (3). 8. Remove the cover to the outlet pipe bolt. 9. Remove the thermostat (2). 10. Clean the mating surfaces of the radiator outlet pipe and the coolant pump cover. INSTALLATION PROCEDURE 1. Install the thermostat (2). NOTICE: Refer to Fastener Notice in Cautions and Notices. 2. Install the cover to the outlet pipe bolt ^ Tighten the bolt to 14 Nm (124 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 1806 3. Install the radiator outlet pipe (1) to oil pan (2). ^ Tighten the outlet pipe to oil pan bolt to 26 Nm (19 ft. lbs.). 4. Connect the radiator hose (1) to the outlet pipe (3). 5. Lower the vehicle. 6. Install the cover to the outlet pipe bolt through the exhaust manifold runners. 7. Install the manifold heat shield. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. 9. Connect the negative battery cable. 10. Inspect for leaks. 11. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 1812 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1813 Brake Fluid: Specifications Brake System DOT 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Brake Fluid Brake Fluid: Service Precautions Brake Fluid CAUTION: Brake fluid may Irritate eyes and skin. In case of contact, take the following actions: ^ Eye contact-rinse thoroughly with water. ^ Skin contact-wash with soap and water. ^ If Ingested-consult a physician Immediately. NOTICE: Brake fluid is extremely damaging to paint. If fluid should accidentally touch a painted surface, immediately wipe fluid from paint and clean the painted surface. Use Delco Supreme II Brake Fluid or an equivalent DOT-3 motor vehicle brake fluid. DOT-5 silicone fluid is not recommended for use in the vehicle's base brake system. DO NOT use DOT-5 brake fluid in the antilock brake system. Always store the brake fluid in a closed container. Reseal brake fluid containers immediately after use. Brake fluid that is left in an open or improperly sealed container will absorb moisture. This may lower the fluid's boiling point and may result in system contamination, corrosion or deterioration of the rubber components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Brake Fluid > Page 1816 Brake Fluid: Service Precautions Substandard Brake Fluid NOTICE: Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone brake fluid. Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components to deteriorate. Keep all fluid containers capped to prevent contamination. IMPORTANT: Improper brake fluid such as, mineral oil or water in the fluid, may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate. Upon inspection, if the primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evidenced by the swollen wheel cylinder piston cups on the drum brake wheel cylinders or the master cylinder cover diaphragm. If deterioration of rubber parts is evident disassemble all hydraulic parts and was with alcohol. Dry these parts with unlubricated compressed air before assembly to keep alcohol out of the system. Replace all rubber parts when in the system, including hoses. Also, when working on the brake mechanisms, check for fluid on the brake linings. If any fluid is found, replace the linings. If the master cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If excessive heat conditions are not found, drain the fluid. Flush, the system with brake fluid. Refill and bleed the system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Hydraulic Clutch Fluid (GM P/N 12345347 or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Page 1820 Clutch Fluid: Service and Repair NOTICE: Do not reuse the fluid that has been bled from a system in order to fill the clutch master cylinder reservoir for the following reasons: 1. The fluid may be aerated 2. The fluid may be contaminated 3. The fluid may contain too much moisture IMPORTANT: Maintain the fluid level in the clutch reservoir to the top step with GM P/N 12345347, or equivalent. 1. Clean dirt and grease from the cap in order to ensure that no foreign substances enter the system. 2. Attach a hose to the bleeder screw on the clutch actuator assembly. Submerge the other end of the hose in a container of Hydraulic Clutch Fluid GM P/N 12345347, or equivalent. 3. Depress the clutch pedal slowly and hold. 4. Loosen the bleeder screw to purge air. 5. ^ Tighten the bleeder screw to 2 Nm (18 inch lbs.) 6. Repeat steps 3 through 5 until air is purged. 7. Fill reservoir to the top step with GM P/N 12345347, or equivalent. 8. Repeat the bleeding procedure if there is a grinding noise during the clutch spin down procedure. Refer to Clutch Spin Down Time. See: Transmission and Drivetrain/Clutch/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1825 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1826 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1827 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1828 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................ 10.0 Liters (10.5 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1831 Coolant: Fluid Type Specifications ENGINE COOLANT A 50/50 mixture of clean water (preferably distilled) and use only GM Goodwrench(R) DEX-COOL(R) or Havoline(R) DEX-COOL(R) (orange-colored, silicate-free) coolant, conforming to GM Specification 6277M. CAUTIONS: ^ The use of sealing pellets (or similar compounds) in the coolant system is NOT recommended.The use of sealing pellets may restrict the flow of coolant through the throttle body or other engine cooling system components. ^ If silicate coolant is added to the cooling system, premature engine, heater core or radiator corrosion may result. In addition, the coolant will require change SOONER, at 50 000 km (30,000 miles) or 24 months. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1832 Coolant: Description and Operation COOLANT DESCRIPTION NOTICE: When adding coolant, it is important that you use GM Goodwrench DEX-COOL or HAVOLINEO DEX-COOL coolant. If Coolant other than DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) is added to the system the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months. A 50/50 mixture of ethylene glycol (DEX-COOL (R) ) and water will provide the follow protection: NOTICE: Pure coolant can be added to raise the boiling point of the coolant, but too much will affect the freezing point. Do not use a solution stronger than 70 percent, as the freeze level rises rapidly after this point. Pure coolant will freeze at-22°C (-8°F). ^ Give freezing protection down to-37°C (-34°F). ^ Give boiling protection up to 129°C (260°F) ^ Help keep the proper engine temperature. ^ Let the warning lights and gauges work correctly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing Coolant: Testing and Inspection Coolant Concentration Testing Coolant testers J26568 Centigrade Scale or J23688 Fahrenheit Scale can be used to verify the antifreeze protection of the coolant. Verify that the refractometer markings are correct. Unless J26568 or J23688 has a provision for temperature correction, test the temperature at which testers are calibrated. IF the coolant is warmer or cooler the reading may be incorrect. Follow the manufacturer's directions on the tester being used. ^ Before each use, lift up the plastic cover at the slanted end of J26568 or J23688 exposing the measuring window and the bottom of the plastic cover. ^ Wipe the window with a tissue or a clean soft cloth. ^ Close the plastic cover. TESTING PROCEDURE ^ Tools Required J26568 or J23688 Coolant Tester Do not remove the clear plastic pump from the tester. 1. Release the tip of the pump from the coolant tester housing. 2. Insert the tip of the pump into the surge tank/radiator. The tip of the pump must be below the level of the coolant. 3. Press the bulb. Release the pump bulb in order to obtain a sample of the coolant. 4. Bend the tube around the J26568 or the J23688. Insert the tip of the pump into the cover plate opening. 5. Press the pump bulb. Allow a few drops to fall onto the measuring surface. Do not open the plastic cover when taking readings because any water evaporation will change the reading. 6. Point the coolant tester toward any light source. Look into the eyepiece. 6.1. The coolant protection reading is at the point where the dividing line between light and dark crosses the scale. Antifreeze protection is the scale on the right. 6.2. The temperature scale is reversed from a standard thermometer scale. 6.3. Below zero readings are on the upper half of the scale. 6.4. If the readings are not clear, properly clean and dry the measuring surface. Conduct a new test. Verify that enough fluid is on the measuring surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing > Page 1835 Coolant: Testing and Inspection Cooling System Leak Testing SURGE TANK CAP PRESSURE TEST ^ Tools Required J24460-01 Cooling System and Cap Pressure Tester - J24460-92 Cooling System Tester Adapter 1. Inspect the hose connections for leaks. 2. Inspect the surge tank cap for loss of pressure using the J24460-92 and the J24460-01.If the surge tank cap does not hold the rated pressure, replace the surge tank pressure cap. 3. Use the correct pressure cap. Use only a 103 kPa (15 psi) pressure cap. ON-VEHICLE PRESSURE TESTING PROCEDURE ^ Tools Required J24460-01 Cooling System and Cap Pressure Tester - J24460-92 Cooling System Tester Adapter 1. Inspect the connections of the coolant hoses for leaks. Repair as required. 2. Remove the surge tank cap. 3. Install J24460-01 to the surge tank. Follow the instructions supplied with the J24460-01. 4. Build up pressure to no more than 138 kPa (20 psi). 5. The system should hold the pressure for about two minutes. ^ If a measurable amount of pressure drops within two minutes, test for a leak. ^ If you find a leak, remove the radiator. Replace the radiator. Refer to Radiator Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1840 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1841 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1842 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1843 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 3T40 Automatic Transaxle Bottom Pan Removal ........................................................................................................................... ............................................... 3.8 Liters (4.0 Quarts) Complete Overhaul .............................................................................................................................. ............................................... 6.6 Liters (7.0 Quarts) Dry ....................................................................................................................................................... ............................................... 8.5 Liters (9.0 Quarts) 4T40-E Automatic Transaxle Bottom Pan Removal ........................................................................................................................... ............................................... 7.0 Liters (7.4 Quarts) Complete Overhaul .............................................................................................................................. ........................................... 10.0 Liters (10.6 Quarts) New Converter ..................................................................................................................................... ............................................... 2.5 Liters (2.6 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1846 Fluid - A/T: Fluid Type Specifications DEXRON-III Automatic Transmission Fluid (or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1847 Checking Oil Level Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle Fluid - A/T: Testing and Inspection 3T40 Transaxle Transmission Fluid Level and Condition Check Important: When you check the fluid level, the fluid will be higher on the indicator when the transmission is cold. Conversely, the fluid level will drop when checked at operating temperature. This is due to the case thermostat element. 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 88°-93°C (190°-200°F). 2. Park the vehicle on a level surface. Apply the parking brake and block the wheels. 3. While the engine is idling and with your foot on the brake, move the shift lever through each gear range, ending in Park. 4. Check the fluid level, color, and condition. 5. If you must add fluid, use DEXRON-III Automatic Transmission Fluid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 1850 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 1851 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 1852 Fluid - A/T: Testing and Inspection 4T40-E Transaxle Transmission Fluid Level and Condition Check (Diagnosis) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 1853 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 1854 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid - A/T: Service and Repair 3T40 Automatic Transaxle Changing Oil and Filter REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place A drain . pan under the transmission Oil Pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the Oil Pan sealing surfaces. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1857 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1858 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 in. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Filler Tube Removal and Installation REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1859 1. Remove the oil level indicator. 2. Remove the nut or bolt that retains the fill tube to the mounting bracket. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a drain pan under the transmission. 5. Loosen the filler tube from the transmission. 6. Remove the filler tube seal. 7. Lower the vehicle. 8. Pull the tube out of the vehicle from the top. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1860 1. Install the filler tube through the top of the vehicle. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Install the filler tube seal into the transmission. Lubricate the seal with DEXRON(R) IIE, or DEXRON(R) III. 4. Install the filler tube into the transmission. 5. Lower the vehicle. 6. Install the nut that retains the tube to the mounting bracket. 7. Install the oil level indicator. 8. Adjust the oil level. Transaxle Fluid Flushing PREPARATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1861 ^ Tools Required J 35944-A Oil Cooler and Line Flusher - J 35944-20 Cooler Flushing Fluid Whenever you remove a transmission for service, do a transmission oil cooler flushing. It is essential to flush the oil cooler under the following conditions: ^ After a major overhaul ^ Suspected contamination ^ Pump or torque converter replacement For complete transmission service, perform the flush procedure after the overhauled or replacement assembly is installed in the vehicle. 1. Remove the fill cap on the J 35944-A. 2. Fill the can with 0.6 liter (20-21 ounces) of J 35944-20, or equivalent, cooler flushing fluid. Do not overfill. If you overfill, the tool will need recharging with air before the backflush. 3. Follow the manufacturer's suggested procedures for proper handling of the solution. IMPORTANT: Shop air supply must not exceed 825 kPa (120 psi), and must be equipped with a water/oil filter. 4. Secure the fill cap, and pressurize the flusher can with shop air to 550-700 kPa (80-100 psi). 5. Connect the J 35944-A to the transmission end of the transmission cooler pipe that feeds the bottom fitting of the oil cooler. 6. Connect the discharge hose to the top oil cooler pipe. 7. Clip the discharge hose to the oil drain container. 8. With the water valve on the tool in the OFF position, connect the water hose from the water supply to the tool. 9. Turn ON the water supply at the faucet. INITIAL FLUSHING IMPORTANT: If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 1. Switch the water valve on the tool to the ON position. Allow the water to flow through the oil cooler for 10 seconds in order to remove the transmission fluid in the system. 2. Switch the water valve on the tool to the OFF position. Clip the discharge hose onto a 5 gallon pail with a lid. If no lid is available, place a shop towel over the end of the hose in order to prevent splash. The discharge will foam vigorously when you introduce solution into the water stream. 3. Switch the water valve on the tool to the ON position. Depress the trigger that mixes the flushing solution into the water flow. Use the bale clip on the handle in order to hold down the trigger. 4. Flush the oil cooler with water and solution for 2 minutes. During the flush, attach the air supply to the air valve on the tool for 3-5 seconds after every 15-20 second interval in order to create a surging action. 5. Release the trigger. Switch the water valve on the tool to the OFF position. 6. Disconnect both hoses from the oil cooler pipes. BACKFLUSH 1. Connect the hoses to the oil cooler pipes in order to perform a backflush. 2. Switch water valve on the tool to the ON position. Depress the trigger in order to mix the flushing solution with the water flow. Use the bale clip on the handle to hold down the trigger. 3. Flush the oil cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve on the tool for 3-5 seconds after each 15-20 second interval in order to create a surging action. 4. Release the trigger. Allow water only to rinse the oil cooler for 1 minute. 5. Turn the water supply OFF at the faucet. 6. Attach the air supply to the air valve on the tool. Dry out the system with air for at least 2 minutes. Dry out the system longer than 2 minutes, if moisture from the oil cooler line discharge hose is visible. 7. Connect the cooler feed pipe to the transmission. The cooler feed is the bottom connection at the transmission. 8. If not already connected, attach the discharge hose to the cooler return pipe. Place the hose into an appropriate drain container. 9. After filling the transmission with DEXRON(R) III or DEXRON(R) IIE automatic transmission fluid, or equivalent, start the engine. Run the engine for 30 seconds. This removes any residual moisture from the oil cooler and the cooler pipes, protects all the components from corrosion, and checks the flow rate through the cooler. 10. You should get a minimum of 1.9 liters (2 quarts) of transmission fluid during this 30 second run. If the flow of fluid is insufficient, disconnect the oil cooler feed line at the radiator and restart the engine. 11. If the flow is insufficient, inspect the transmission for cause. Inspect the cooler pipes and fittings. Repeat the cooler flushing procedure. Replace the cooler if the flow is still insufficient. 12. Remove the discharge hose. 13. Reconnect the cooler return pipe to the transmission. 14. Refill the unit to the proper fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1862 Fluid - A/T: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure at Testing and Inspection. See: Testing and Inspection 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1863 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1864 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 in. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transaxle ................................................................................................................................ ............................................... 1.9 Liters (2.0 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1869 Fluid - M/T: Fluid Type Specifications DEXRON Synchromesh Transmission Fluid (GM P/N 12345349 or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1870 Fluid - M/T: Testing and Inspection INSPECTION PROCEDURE IMPORTANT: ^ Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. ^ The fluid level indicator must be fully seated during vehicle operation or leakage will occur at the vent plug. 1. Remove the fluid level indicator. 2. Read the fluid level indicator. 3. If the indicator reads ADD or below, fill the transaxle to FULL with synchromesh transaxle fluid GM P/N 12345349 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1871 Fluid - M/T: Service and Repair INSPECTION PROCEDURE IMPORTANT: ^ Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. ^ The fluid level indicator must be fully seated during vehicle operation or leakage will occur at the vent plug. 1. Remove the fluid level indicator. 2. Read the fluid level indicator. 3. If the indicator reads ADD or below, fill the transaxle to FULL with synchromesh transaxle fluid GM P/N 12345349 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1876 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1877 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity Without Filter Change ........................................................................................................................................................... 3.473L (3.5 Qts.) When Changing the Oil Filter, Up To An Additional 0.473 Liter Or One Half Quart Of Oil May Be Needed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1880 Engine Oil: Fluid Type Specifications ENGINE OIL VISCOSITY All Temperatures ................................................................................................................................. ............................................ SAE 5W-30 (Preferred) Above 0°F (-18°C) ............................................ .............................................................................................................................................. SAE 10W-30 Using oils of any viscosity other than those viscosity's recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. The recommended oil viscosity for all vehicles when the temperature is above -18° C (0° F) is SAE 1OW-30. Engine oil viscosity (thickness) has an effect on the fuel economy and the cold-weather operation (starting and oil flow). Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather condition require higher viscosity engine oils for satisfactory lubrication. When the temperature will be very cold and never above 16° C (60° F), SAE 5W-30 should be used in all models. In areas of the world other than North America, it may be difficult to find oils that display the API STARBURST symbol and that are labeled as meeting the GM4718M Specification. If you cannot find API STARBURST displaying oils identified as meeting the GM4718M requirements, look for oils that meet the API Service SJ and ACEA A3-96 requirements. The recommended SAE engine oil viscosity is 5W-30, however, additional engine oil viscosities meeting the API Service SJ and ACEA A3-96 requirements may be used in accordance with the temperature ranges as shown in figure 3. NOTE: SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any vehicles at any time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1881 Engine Oil: Service Precautions Look for and use ONLY the engine oil that meet GM Specification. Oil that does not have the correct specification designation can cause engine damage not covered by the warranty. Do NOT use engine oil additives. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1882 Engine Oil: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan bolt. 4. Remove the oil filter. INSTALLATION PROCEDURE 1. Install the oil filter. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the oil pan drain bolt. ^ Tighten the oil pan drain bolt to 26 Nm (19 ft. lbs.). Lower the vehicle. 3. Fill the engine with oil to the appropriate mark. 4. Install negative battery cable. 5. Start engine and inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications GM Power Steering Fluid (GM P/N 1052884 - 1 pint or 1050017 - 1 quart, or equivalent). In cold climates use (GM P/N 12345866 - one pint, GM P/N 12345867 - one quart, or equivalent). NOTE: The system should be flushed and bled prior to switching fluid types. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1890 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1891 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1892 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1893 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Charge Capacity 1.5 lb (US) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1896 Refrigerant: Fluid Type Specifications Refrigerant Type R-134a GM P/N 12345922 Or Equivalent Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1897 Refrigerant: Service Precautions Refrigerant drums have a heavy metal cap. The cap protects the valve and safety plug from damage.For this reason, always replace the cap after each use. Whenever a container of refrigerant must be carried in a vehicle, do not carry it in the passenger compartment. See the manufacturers guidelines for storage, transportation and the maximum temperature to which the container can be exposed. When filling a small refrigerant drum from a large one, never fill the smaller drum completely. Always leave space for the liquid to expand. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1898 Refrigerant: Description and Operation The air conditioning system contains Refrigerant-134a, which requires special handling to avoid personal injury. Refer to Handling Refrigerant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Refrigerant Oil Capacity Polyalkaline Glycol (PAG) Synthetic Refrigerant Lubricant 9 oz (US) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1905 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Polyalkylene Glycol (PAG) Synthetic Refrigerant Lubricant Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure Brake Bleeding: Service and Repair Motor Rehome Procedure REHOME TEST The motor rehome function will return all of the hydraulic modulator pistons to their upmost home, position. This allows all fluid paths within the modulator to be open so that the modulator can be properly bled. The motor rehome function must ALWAYS be used prior to bleeding the brake system IMPORTANT: The motor rehome function cannot be performed if any current DTCs are present. If current DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 1910 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding CAUTION: Do not move the vehicle until a firm brake pedal is obtained. Air In the brake system can cause the loss of brakes with possible personal injury. A bleeding operation is necessary in order to remove air from the hydraulic brake system whenever air is introduced into the brake system. Bleed the hydraulic system at all four brakes if air has been introduced into the system through low fluid level or by disconnecting the brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, bleed only that wheel cylinder/caliper. If the pipes are disconnected at any fitting located between the master cylinder and brakes, bleed the brake system served by the disconnected pipe. Observe the following steps in order to reduce the time required to bleed the hydraulic system: ^ Ensure that the master cylinder reservoir is filled with brake fluid. ^ Expel as much air as possible before installing the master cylinder on the vehicle. MANUAL BLEEDING Tools Required ^ J 21472 Brake Bleeder Wrench Apply the brakes several times with the ignition OFF. This will deplete the vacuum reserve. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with the specified brake fluid in Maintenance and Lubrication in General Information. ^ Maintain the fluid level in the reservoir during the bleeding operation. ^ Use an assistant in the vehicle in order to press the brake pedal during the manual bleeding process. 2. If the master cylinder is known or suspected to have air in the bore, bleed the master cylinder before the wheel cylinder or the calipers are bled. Complete the following steps: 3. Disconnect the forward brake pipe connections) (1) at the master cylinder. 4. Fill the master cylinder with brake fluid until fluid begins to flow from the forward pipe connector port. 5. Connect the forward brake pipe to the master cylinder. Tighten the pipe. 6. Slowly depress the brake pedal and hold the pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 1911 7. Loosen the forward brake pipe connection at the master cylinder in order to purge air from the cylinder. 8. Tighten the connection. 9. Slowly release the brake pedal. 10. Wait 15 seconds. 11. Repeat the previous eight steps until all air is removed from the bore. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 12. Bleed the master cylinder at the rear (cowl end) connections after all the air has been removed at the forward connections. Slowly depress the brake pedal and hold the pedal. 13. Check for a firm pedal feel and proper brake pedal travel. If the wheel cylinders and calipers do not contain air, bleeding is not necessary, but recommended in order to remove any moisture or debris. 14. After all air is removed from the master cylinder, bleed the wheel cylinders in the following order, if necessary: 14.1. Right rear 14.2. Left rear 14.3. Right front 14.4. Left front 15. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 16. Place a proper size box end wrench (1) (or special tool) over the caliper/cylinder bleeder valve. 17. Attach a transparent tube (2) over the bleeder screw. Submerge the other end in a transparent container partially filled with clean brake fluid. 18. Slowly depress the brake pedal and hold the pedal. 19. Loosen the bleeder screw in order to purge the air from the cylinder/caliper. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 20. Tighten the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (62 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm (115 inch lbs.). 21. Slowly release the pedal. 22. Wait 15 seconds. 23. Repeat the previous five steps until all air is removed from the caliper. Do not pump the brake pedal rapidly. Pumping the pedal pushes the master cylinder secondary piston down the bore which causes difficult bleeding. 24. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 1912 25. Fill the master cylinder to the proper level. 26. Check the brake pedal for sponginess or excessive travel. Repeat the entire manual bleeding procedure in order to correct either of the two conditions. PRESSURE BLEEDING Tools Required ^ J 29532 Diaphragm Type Brake Bleeder ^ J 35589 pressure Bleeder Adapter Cap ^ J 21472 Brake Bleeder Wrench NOTICE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install the J 35589 to the master cylinder 2. Charge the J 29532 to 140-172 kPa (20-25 psi). 3. Connect the line to the J 35589. 4. Open the line valve. 5. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 6. Bleed the wheel cylinders/calipers in the following order, if necessary: 6.1. Right rear 6.2. Left rear 6.3. Right front 6.4. Left front 7. Place the J 21472 over the caliper/cylinder bleeder valve. 8. Attach a transparent tube over the bleeder screw. Submerge the opposite hose end in a transparent container partially filled with clean brake fluid. 9. Open the bleeder screw at least 3/4 of a turn. Allow the fluid to flow until no air is visible in the fluid. 10. Close the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (6.2 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm ( 115 inch lbs.). 11. Repeat the previous four steps until all of the calipers/cylinders have been bled. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 1913 12. Lower the vehicle. 13. Inspect the brake pedal for sponginess. Repeat this entire pressure bleeding procedure in order to correct this conditions. 14. Remove the J 35589 and the J 29532. 15. Fill the master cylinder to the proper level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1918 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1919 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1920 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1921 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: Customer Interest Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: All Technical Service Bulletins Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1947 Fuse: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1948 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1949 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 1952 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications > Electrical Specifications Fuse Block: Electrical Specifications Front View Of Engine Compartment Fuse/Relay Center Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications > Electrical Specifications > Page 1957 Fuse Block: Mechanical Specifications Convenience Center to I/P .................................................................................................................. ............................................................6 N.m (53 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center Convenience Center At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1960 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1961 Fuse Block: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > C1 Fuse Block: Diagrams C1 Convenience Center (C1) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > C1 > Page 1964 Convenience Center (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > C1 > Page 1965 Convenience Center (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 1968 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1969 Fuse Block: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Remove the battery ground negative cable. 2. Remove the instrument panel compartment. 3. Remove the instrument panel access hole cover from the instrument panel. 4. Remove the electrical connectors. 5. Remove the fuse block from the tie bar (6). 6. Remove the fuse block (5) from the instrument panel. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1970 1. Install the fuse block (5) to the instrument panel. 2. Install the fuse block to the tie bar (2). 3. Install the electrical connectors. 4. Install the right instrument panel access hole cover to the instrument panel. 5. Install the battery ground negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 1979 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > System Information > Service Precautions Service Reminder Indicators: Service Precautions SERVICE PRECAUTION All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the indicator is ignored. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE Caution: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack. Caution: To help avoid personal injury, when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which you are removing components. The additional support will reduce the possibility of the vehicle falling off the hoist. When you are removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads at the same end from which you are removing the major components to prevent tip-off. If you fail to follow these precautionary measures, vehicle damage, serious personal injury, or death may result. Notice: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair All vehicles are equipped with a high pressure compact spare tire. The compact spare tire uses a narrow 4-inch wide rim, although the wheel diameter is usually one inch larger than the road wheels. Do not use the compact spare tire with standard tires, snow tires, wheel covers or trim rings. If such use is attempted, damage to these items or other parts of the vehicle may occur. Use the compact spare tire only on vehicles which offered the spare tire as the original equipment. CAUTION: To avoid serious personal injury, do not stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when Inflating any tire If beads are not seated If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. Periodically check inflation pressure. Maintain inflation pressure at 415 kPa (60 psi). The compact spare tire can be mounted and dismounted from the wheel using present tire changing equipment and procedures. As with other tires, completely seat the beads at 275 kPa (40 psi). The tire may then be safely inflated to 415 kPa (60 psi). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1999 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2000 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2001 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2006 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2012 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2013 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2014 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2019 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2024 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2025 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2030 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2031 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2032 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2037 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2055 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2056 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2057 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2062 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2067 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2068 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2081 Wheels: Specifications Maximum Radial Runout: Steel Wheel ......................................................................................................................................... ............................................. 1.01 mm (0.040 inch) Aluminum Wheels ............................................... ............................................................................................................................ 0.76 mm (0.030 inch) Maximum Lateral Runout: Steel Wheels ....................................................................................................................................... ............................................. 1.14 mm (0.045 inch) Aluminum Wheels ............................................... ............................................................................................................................ 0.76 mm (0.030 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description Wheels: Description and Operation General Description The factory installed tires and wheels are designed to operate with loads up to and including the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures, wheel alignment and driving techniques have an important influence on tire life. Heavy cornering, excessive rapid acceleration, and heavy braking will increase tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description > Page 2084 Wheels: Description and Operation Wheel Repair Description Wheel repairs that use welding, heating or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. Porosity in aluminum wheels can be repaired. Refer to ALUMINUM WHEEL POROSITY REPAIR. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description > Page 2085 Wheels: Description and Operation Wheels Description Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if the wheel nuts won't stay tight, or if wheel nuts are heavily rusted. Wheels with excessive runout may cause objectionable vibrations. Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset, and mounting configuration. A wheel of improper size or type may affect wheel and bearing life, brake cooling, speedometer/odometer calibration, vehicle ground clearance, and tire clearance to the body and chassis. Steel wheels can be identified by a two or three-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal Wheels: Service and Repair Removal Penetrating oil is not effective in removing tight wheels. However, if it is used, apply sparingly to the center hole area of the wheel only. CAUTION: If penetrating all gets on the vertical surfaces between the wheel and the rotor or drum, it could cause the wheel to work loose as the vehicle is driven, resulting In a loss of control and an Injury accident. Wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force, such as hammering the wheel or tire, can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. REMOVAL PROCEDURE Using the following procedure, the wheel can be removed without damage. 1. Tighten all of the wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle from side to side. If this is not effective go to the next step. If this procedure is effective, go to Step 3. 2. Rock the vehicle from Drive to Reverse, allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal in order to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more person's body weight. If the wheel is still tight, repeat the procedure. 3. Raise the vehicle and suitably support the vehicle. 4. Remove the wheel cover. 5. Remove the wheel nuts. 6. Mark the location of the tire and wheel assembly to the hub assembly. 7. Clean the wheel nuts, studs and the wheel and brake chum or rotor mounting surfaces. CAUTION: Before Installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2088 Wheels: Service and Repair Installation INSTALLATION PROCEDURE 1. Install the cap on the aluminum wheel, if necessary. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. 3. Align the locating mark of the tire and the wheel with the hub assembly. CAUTION: Never use all or grease on studs or nuts. Tighten the wheel nuts with your fingers unto they are snug. Then, tighten the nuts (In the sequence shown) to the fastener tightening specification shown in SPECIFICATIONS. Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury, and property damage. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the wheel nuts. Tighten Tighten the wheel nuts in sequence to 140 Nm (100 ft. lbs.). 5. Install the wheel cover, if equipped. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2089 Wheels: Service and Repair Aluminum Wheel Hub Cap Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Use the following procedure in order to remove the hub cap: ^ Place a block of wood, approximately 50 mm (2 in) in diameter with a squared off end, against the back surface of the cap. ^ Strike the block of wood sharply with a hammer in order to remove the cap. INSTALLATION PROCEDURE 1. Install the hub cap using the following procedure: ^ Place the cap into position at the wheel opening. ^ Place a block of wood, at least 75 mm t3 in), on the diameter against the cap face. NOTICE: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. ^ Install the cap by striking the block of wood with a harmer. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2090 Wheels: Service and Repair Aluminum Wheel Porosity Repair 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Locate the leaking areas by inflating the tire to 275 kPa (40 psi) and dipping the tire and the wheel assembly into a water bath. 4. Mark the leak areas and remove the tire from the wheel. Refer to TIRE MOUNTING AND DISMOUNTING. 5. Scuff the inside of the rim surface at the leak area with 80 number grit sandpaper. Clean the area with general purpose cleaner. 6. Apply a 3 mm (1/8 inch) thick layer of adhesive/sealant to the leak area and allow six hours of drying time. 7. Mount the tire on the wheel. Pressurize the tire to 275 kPa (40 psi) and check for leaks. Refer to TIRE MOUNTING AND DISMOUNTING. CAUTION: To avoid serious personal Injury, do nor stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal Injury. 8. Adjust the tire pressure in order to meet specifications. 9. Balance the tire and the wheel assembly. 10. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2091 Wheels: Service and Repair Removal Penetrating oil is not effective in removing tight wheels. However, if it is used, apply sparingly to the center hole area of the wheel only. CAUTION: If penetrating all gets on the vertical surfaces between the wheel and the rotor or drum, it could cause the wheel to work loose as the vehicle is driven, resulting In a loss of control and an Injury accident. Wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force, such as hammering the wheel or tire, can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. REMOVAL PROCEDURE Using the following procedure, the wheel can be removed without damage. 1. Tighten all of the wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle from side to side. If this is not effective go to the next step. If this procedure is effective, go to Step 3. 2. Rock the vehicle from Drive to Reverse, allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal in order to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more person's body weight. If the wheel is still tight, repeat the procedure. 3. Raise the vehicle and suitably support the vehicle. 4. Remove the wheel cover. 5. Remove the wheel nuts. 6. Mark the location of the tire and wheel assembly to the hub assembly. 7. Clean the wheel nuts, studs and the wheel and brake chum or rotor mounting surfaces. CAUTION: Before Installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Installation INSTALLATION PROCEDURE 1. Install the cap on the aluminum wheel, if necessary. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. 3. Align the locating mark of the tire and the wheel with the hub assembly. CAUTION: Never use all or grease on studs or nuts. Tighten the wheel nuts with your fingers unto they are snug. Then, tighten the nuts (In the sequence shown) to the fastener tightening specification shown in SPECIFICATIONS. Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury, and property damage. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the wheel nuts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2092 Tighten Tighten the wheel nuts in sequence to 140 Nm (100 ft. lbs.). 5. Install the wheel cover, if equipped. 6. Lower the vehicle. Aluminum Wheel Hub Cap Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Use the following procedure in order to remove the hub cap: ^ Place a block of wood, approximately 50 mm (2 in) in diameter with a squared off end, against the back surface of the cap. ^ Strike the block of wood sharply with a hammer in order to remove the cap. INSTALLATION PROCEDURE 1. Install the hub cap using the following procedure: ^ Place the cap into position at the wheel opening. ^ Place a block of wood, at least 75 mm t3 in), on the diameter against the cap face. NOTICE: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. ^ Install the cap by striking the block of wood with a harmer. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Aluminum Wheel Porosity Repair 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Locate the leaking areas by inflating the tire to 275 kPa (40 psi) and dipping the tire and the wheel assembly into a water bath. 4. Mark the leak areas and remove the tire from the wheel. Refer to TIRE MOUNTING AND DISMOUNTING. 5. Scuff the inside of the rim surface at the leak area with 80 number grit sandpaper. Clean the area with general purpose cleaner. 6. Apply a 3 mm (1/8 inch) thick layer of adhesive/sealant to the leak area and allow six hours of drying time. 7. Mount the tire on the wheel. Pressurize the tire to 275 kPa (40 psi) and check for leaks. Refer to TIRE MOUNTING AND DISMOUNTING. CAUTION: To avoid serious personal Injury, do nor stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal Injury. 8. Adjust the tire pressure in order to meet specifications. 9. Balance the tire and the wheel assembly. 10. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Aluminum Wheel Refinishing A protective clear or color coating is applied to the surface of original equipment cast aluminum wheels. A surface degradation condition can begin to develop if this clear coating is damaged or removed. This can happen at some automatic car wash facilities using aggressive silicon carbide tipped tire brushes in order to clean the white walls and the tires. Once the protective coating is damaged, exposure to caustic cleaners and/or road salt causes further surface degradation. The following procedure details how to strip, clean and coat the aluminum wheels that are affected by these conditions. Use the listed materials when completing this procedure. ^ Amchem Alumi Prep number 33 - stock number DX533 or the equivalent - cleaning and conditioning chemical for aluminum. ^ Amchem Alodine number 1001 - stock number DX50T or the equivalent-coating chemical for aluminum. ^ Ditzler Delclear Acrylic Urethane Clear - stock number DAU-75 or equivalent. ^ Ditzler Delthane Ultra-Urethane Additive - stock DXR-80 or equivalent. REMOVAL PROCEDURE 1. Remove the tire and the wheel assembly from the vehicle. Refer to WHEEL REMOVAL. 2. Match mark the tire for reinstallation of the outboard wheel weights after the recoating of the wheel. 3. Remove the outboard wheel weights. 4. Clean the inside and the outside of the wheel with a water base all purpose cleaner. 5. Remove grease or oil from the wheel with a solvent cleaner. SURFACE DAMAGE CAUTION: Do not use vehicle power to rotate the wheel while sanding to avoid personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2093 1. Sand over painted areas that do not require recoloring with number 400 (wet or dry) in order to promote adhesion of a clear coat. 2. Mount the tire and the wheel on a brake lathe and spin slowly. NOTICE: Do not use an abrasive coarser than 80 grit or wheel may be damaged. 3. Sand wheel with a backing block or a pad by holding the abrasive flat in order to the surface of the wheel and moving slowly back and forth from the center to the outer edge to remove damage. Use the following sandpaper grits in the order listed: 3.1. Sand with number 80 grit sandpaper. 3.2. Sand with number 150 grit sandpaper. 3.3. Sand with number 240 grit sandpaper. RE-COATING PROCEDURE CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal injury. 1. Clean the surface of the contaminants by washing the surface with soap and water. 2. Spray the wheel with Amchem number 33 or the equivalent. 3. Let the wheel soak for 1 to 3 minutes. 4. Rinse the wheel with water. Blow the wheel dry with compressed air. 5. Soak the wheel with Amchem number 1001 or the equivalent. 6. Let the wheel soak for 1 to 3 minutes. 7. Rinse the wheel with water. Blow the wheel dry with compressed air. 8. Mask off the tire. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 9. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or the equivalent using the following three coats. Refer to the labels for specific instructions: ^ First coat-light mist coat, let flash. ^ Second coat-light, let flash. ^ Third coat-heavy double wet coat. 10. Let the wheel dry for 24 hours (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALLATION PROCEDURE 1. Balance the tire and the wheel assembly. 2. Replace the original balance weights with nylon coated weights in order to avoid discoloration of the wheel. 3. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Clearcoat Damage to Aluminum Wheels UNPAINTED WHEELS 1. Remove the wheel and tire assembly from the vehicle. Refer to WHEEL REMOVAL. 2. Match mark the tire for reinstallation of the outboard wheel weights after the recoating of the wheel. 3. Remove the outboard wheel weights. 4. Clean the wheel inside and out with a water base all purpose cleaner. 5. Remove the grease or the oil with a solvent cleaner. 6. Sand over painted areas that do not require recoloring with number 400 (wet or dry) to promote adhesion of clear coat. CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 7. Apply the chemical stripper. 8. Allow the stripper to penetrate the coating. 9. Use a small 1/4 inch-detail brush dipped in stripper in order to apply the material around the perimeter and the spoke-like areas. 10. Remove the stripper following the manufacturer's recommendations. CAUTION: Do not use vehicle power to rotate the wheel walls sanding to avoid personal Injury. 11. Sand the wheel with 240 grit while rotating the wheel on a slow spinning brake lathe or by mounting on the vehicle and spinning by hand. This will restore the machined appearance and promote adhesion. CAUTION: Use of rubber gloves and eye protection Is necessary to prevent personal injury. 12. Clean the surface of the contaminants by washing the surface with soap and water. 13. Spray the wheel with Amchem number 33 or the equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 2094 14. Let the wheel soak for 1 to 3 minutes. 15. Rinse the wheel with water. Blow the wheel dry with compressed air. 16. Soak the wheel with Amchem number 1001 or the equivalent. 17. Let the wheel soak for 1 to 3 minutes. 18. Rinse the wheel with water. Blow the wheel dry with compressed air. 19. Mask off the tire. 20. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or the equivalent using the following three coats. Refer to the labels for specific instructions. ^ First coat-light mist coat, let flash. ^ Second coat-light, let flash. ^ Third coat-heavy double wet coat. 21. Let the wheel dry for 24 hours (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALLATION PROCEDURE 1. Balance the wheel and the tire assembly. 2. Replace the original balance weights with nylon coated weights in order to avoid discoloration of the wheel. 3. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT WHEEL BEARINGS AND/OR HUB REMOVAL PROCEDURE ^ Tools Required: J 28733-B Front Hub Spindle Remover 1. Remove the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in Drive Axles, Bearings and Joints. 2. Remove brake caliper bolts and support caliper. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 3. Remove the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Remove the bolts (1) from the hub and bearing assembly (3). 5. Remove the hub and bearing assembly (1) from the steering knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2100 1. Install the hub and bearing assembly (1) into the steering knuckle (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the hub and bearing bolts (1) and washers (2). Tighten Tighten the bolts to 95 Nm (70 ft. lbs.). 3. Install the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Install the brake caliper and bolts. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 5. Install the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in DRIVE AXLES, BEARINGS AND JOINTS. 6. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2101 Wheel Bearing: Service and Repair Rear REAR HUB AND/OR BEARINGS REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the brake drum. Refer To BRAKE DRUM REPLACEMENT. 4. Remove the hub and bearing assembly (4) from the axle (2). The top rear attaching bolt (5) and nut (1) will not clear the brake shoe (3) when removing the hub and bearing assembly. Partially remove the hub and bearing assembly prior to removing this bolt. 5. Disconnect the rear ABS wheel speed sensor wire connector. INSTALLATION PROCEDURE 1. Connect the rear ABS wheel speed sensor wire connector. 2. Install the hub and bearing assembly (4). Position the top rear attaching bolt (5) in the hub and bearing assembly prior to the installation in the axle assembly (2). Tighten Tighten the hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 4. Install the tire and wheel assemblies. Refer to WHEEL REMOVAL. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Specifications Wheel Cover: Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Drive Axle Nut 200 Nm (144 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 2110 Axle Nut: Specifications Rear Hub and Bearing to Axle Bolts 60 Nm (44 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: Recalls Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2124 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2130 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: All Technical Service Bulletins Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2140 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: All Technical Service Bulletins Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Tightening Torque All Wheel Nuts ..................................................................................................................................... ............................................... 140 N.m (100 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 2148 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2149 Wheel Fastener: Description and Operation All models use metric wheel nuts and wheel studs. The nut will have the word metric stamped on the face and the stud will have the letter M stamped into the threaded end. The word metric is stamped on the head. The thread size of the metric wheel nuts and wheel studs are M 12 x 1.5 This signifies: ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters per thread If a broken stud is found, refer to FRONT SUSPENSION or DRIVE AXLE for the replacement procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension REMOVAL PROCEDURE ^ Tools Required: J 6627-A Wheel Stud Remover - J 28733-A Front Hub Spindle Remover 1. Remove the hub and bearing assembly (2). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 2. Remove the wheel stud (1) from the hub and bearing assembly using the J 6627-A. 3. Discard the stud. INSTALLATION PROCEDURE 1. Install the new wheel stud (1) into the hub and bearing assembly (2). 2. Install the flat washers (3) and nut, flat side down, onto the wheel stud. Tighten until the wheel stud is fully seated. 3. Install the hub and bearing assembly. Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 4. Check the front wheel alignment. Refer to MEASURING WHEEL ALIGNMENT (FRONT ALIGNMENT ANGLES). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2152 Wheel Fastener: Service and Repair Rear Suspension REMOVAL PROCEDURE ^ Tools Required: J 6627-A Wheel Stud Remover 1. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 2. Remove the brake drum. Refer to BRAKE DRUM REPLACEMENT. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the wheel stud (2) using the J 6627-A. 4. Discard the wheel stud (2). INSTALLATION PROCEDURE 1. Install the new stud from the back side of the hub. 2. Install the four flat washers (1) on the hub. 3. Install the wheel nut (2) with the flat side toward the washers (1). 4. Tighten the nut (2) until the stud head is properly seated in the hub flange. 5. Remove the nut (2) and the washers (1). 6. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 7. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2157 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2158 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2159 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2160 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2161 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2162 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE Caution: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack. Caution: To help avoid personal injury, when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which you are removing components. The additional support will reduce the possibility of the vehicle falling off the hoist. When you are removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads at the same end from which you are removing the major components to prevent tip-off. If you fail to follow these precautionary measures, vehicle damage, serious personal injury, or death may result. Notice: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2171 Compression Check: Testing and Inspection ENGINE COMPRESSION TEST Perform the following steps in order to conduct a compression test for VIN 4: 1. Conduct the following steps in order to check cylinder compression: 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module. 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). IMPORTANT: The results of a compression test will fall into the following categories: ^ Normal-Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings-Compression low on first stroke. Tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. ^ Valves-Compression low on first stroke. Does not tend to build up on the following strokes. Does not improve much with addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Journal Diameter ................................................................................................................................................... 47.453 - 47.478 mm (1.868 - 1.869 inch) Journal Clearance .................................................................................................................................................. 0.013 - 0.089 mm (0.0005 - 0.0035 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear Bolt Torque Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt Torque Camshaft Sprocket Bolt ....................................................................................................................... ................................................... 130 Nm (96 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear Bolt Torque > Page 2180 Camshaft Gear/Sprocket: Specifications Fastener Tightening Specifications Camshaft Sprocket .............................................................................................................................. .................................................... 130 Nm (96 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Camshaft Thrust Plate Bolts ................................................................................................................ ................................................ 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications Camshaft: Specifications Engine Mechanical Specifications Camshaft Lobe Lift: Inlet and Exhaust ................................................................................................................................. .......................................... 6.685 mm (0.263 inch) Journal Diameter ................................................................................................................................................... 47.453 - 47.478 mm (1.868 - 1.869 inch) Journal Clearance .................................................................................................................................................. 0.013 - 0.089 mm (0.0005 - 0.0035 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Engine Mechanical Specifications > Page 2188 Camshaft: Specifications Fastener Tightening Specifications Camshaft Rear Cover Bolts ................................................................................................................. ................................................ 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2189 Camshaft: Service and Repair REMOVAL PROCEDURE 1. Remove the engine assembly. 2. Place the engine on a stand. 3. Remove the drive belt. 4. Remove the generator. 5. Remove the generator brackets. 6. Remove the power steering pump. 7. Remove the drive belt tensioner. 8. Remove the coolant pump pulley. 9. Remove the engine oil and the filter. 10. Remove the crankshaft pulley and the crankshaft pulley hub. 11. Remove the valve rocker arm cover. 12. Remove the rocker arm and pushrod. 13. Remove the valve lifter. 14. Remove the crankcase front cover. 15. Remove the following components. 15.1. Remove the cam sprocket. 15.2. Remove the timing chain. 15.3. Remove the tensioner. 16. Remove the oil pump drive. 17. Remove the thrust plate. 18. Remove the camshaft position sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2190 19. Remove the camshaft. Do not damage the camshaft bearings with the camshaft. INSTALLATION PROCEDURE 1. Coat the camshaft lobes and bearings with GM E.O.S. P/N 1051396 or equivalent. 2. Install the camshaft with extreme care to avoid damage to the camshaft bearings. 3. Install the camshaft position sensor. NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2191 4. Install the thrust plate. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 5. Install the following components. 5.1. Install the tensioner. 5.2. Install the timing chain. 5.3. Install the sprockets. 6. Install the crankcase front cover. 7. Install the valve lifters in the same bores from which they were removed. 8. Install the oil pump drive. 9. Install the rocker arm and pushrod. 10. Install the valve rocker arm cover. 11. Install the crankshaft pulley hub. 12. Install the coolant pump pulley and the crankshaft pulley hub. 13. Install the drive belt tensioner. 14. Install the power steering pump. 15. Install the generator. 16. Install the generator brackets. 17. Install the drive belt. 18. Install the engine assembly. 19. Install the oil filter. 20. Fill the engine with oil. 21. Fill the cooling system. Refer to Draining and Filling Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair REMOVAL PROCEDURE 1. Remove the valve rocker arm cover. 2. Loosen the rocker arm nut. Position the rocker arm aside. 3. Remove the pushrod. 4. Remove the engine lift bracket located at the rear of the engine. 5. Route the spark plug wires below the lower intake manifold. 6. Remove the cylinder head. Refer to Cylinder Head Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2195 7. Remove the cylinder head gasket. 8. Remove the anti-rotation brackets. IMPORTANT: Hydraulic Valve lifters do not require adjustment. Valve lifters must be kept in order so they may be reinstalled in their original position. 9. Remove the valve lifters. INSTALLATION PROCEDURE NOTICE: If the valve lifters and anti-rotation brackets are not installed properly, the valve lifters, the anti-rotation brackets, and the engine could be damaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2196 IMPORTANT: When installing new valve lifters, coat the lifters with camshaft assembly lube (GM P/N 1052365) or equivalent. 1. Install the valve lifters in the lifter bores. ^ Align the flat sides (top) of the lifters with the flat sides of the anti-rotation brackets. ^ When properly aligned, the flat side of each lifter is aligned parallel to the anti-rotation bracket. ^ The roller at the bottom of each lifter is aligned parallel to the camshaft lobe. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the anti-rotation brackets on the valve lifters. ^ Tighten the anti-rotation bracket screws to 11 Nm (97 inch lbs.). 3. Install the cylinder head gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2197 4. Install the cylinder head. 5. Install the lift bracket. 6. Install the lift bracket nut. ^ Tighten the nut to 50 Nm (37 ft. lbs.). 7. Route the spark plug wires up through the lower intake manifold. 8. Install the Pushrods. Ensure that the pushrods seat in the lifter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2198 9. Position the rocker arms. 10. Install the rocker arm bolts. ^ Tighten the nuts to 25 Nm (19 ft. lbs.). 11. Install the valve rocker arm cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications SERVICE SPECIFICATIONS Rocker Arm Ratio ................................................................................................................................ ......................................................................... 1.6 TORQUE SPECIFICATIONS Rocker Arm Bolts ................................................................................................................................. ................................................ 25 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2202 Rocker Arm Assembly: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Remove the valve rocker arm cover. IMPORTANT: Place the components in a rack in order of disassembly so they can be reinstalled at the same location and with the same mating surface as when removed. 3. Remove the rocker arm bolt. 4. Remove the rocker arm. 5. Remove the pushrod. INSTALLATION PROCEDURE IMPORTANT: Whenever new rocker arms and/or rocker arm balls are being installed, coat the bearing surfaces of the rocker arms and the rocker arm balls with camshaft assembly lube GM P/N 1052365 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2203 1. Install the pushrods, making sure that they seat in the lifters. 2. Install the rocker arms. 3. Apply Dri-Slide Moly lubricant GM P/N 1052948 or equivalent to the threads of the bolts. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the rocker arm bolts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 5. Install the valve rocker arm cover. 6. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Rod Bearing Journal Clearance ........................................................................................................................... 0.025 - 0.079 mm (0.00098 - 0.0031 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Dimensions Connecting Rod: Specifications Connecting Rod Dimensions Connecting Rod Rod Side Clearance ............................................................................................................................................... 0.10 0.38 mm (0.0039 - 0.0149 inch) Piston Pin Diameter ........................................................................................................................................................ 20.320 - 20.325 mm (0.8000 - 0.8002 inch) Clearance In Piston ......................................................................................................................................... 0.008 0.0016 mm (0.0003 - 0.0006 inch) Interference Fit In Rod .................................................................................................................................... 0.025 - 0.045 mm (0.00098 - 0.0017 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Dimensions > Page 2212 Connecting Rod: Specifications Connecting Rod Nut Connecting Rod Cap Nuts ................................................................................................................... ..................................................... 52 Nm (38 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Water Jacket Drain Plug ...................................................................................................................... ..................................................... 15 Nm (11 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Pulley/Gear Torque Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley/Gear Torque Crankshaft Pulley Hub To Crankshaft Bolts .............................................................................................................................................. 105 Nm (77 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Pulley/Gear Torque > Page 2220 Crankshaft Gear/Sprocket: Specifications Crankshaft Gear/Hub Torque-Specifications Crankshaft Pulley Hub To Crankshaft Bolts .............................................................................................................................................. 105 Nm (77 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Dimension/Clearance Specifications Crankshaft Main Bearing: Specifications Main Bearing Dimension/Clearance Specifications Main Bearing Clearance ........................................................................................................................................ 0.015 0.047 mm (0.0006 - 0.0019 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Dimension/Clearance Specifications > Page 2225 Crankshaft Main Bearing: Specifications Main Bearing Cap Torque Install the crankshaft bearing caps to the engine block. NOTICE: Refer to Fastener Notice in Service Precautions. Install the crankshaft bearing cap bolts to the engine block. ^ Tighten the crankshaft bearing cap bolts first to 50 Nm (37 ft. lbs.). Before installing the rear crankshaft bearing cap, coat the face of the block where it mates to the cap with sealer GM P/N 1052942. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Dimension/Clearance Specifications > Page 2226 Measure the crankshaft end play using the following procedure: 1. Firmly thrust the crankshaft rearward. 2. Firmly thrust the crankshaft forward. 3. This will align the crankshaft bearing and the crankshaft thrust surfaces. ^ Tighten the crankshaft bearing cap bolts to 95 Nm (70 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Journal: Diameter ........................................................................................................................................................ 63.360 - 63.384 mm (2.4945 - 2.4954 inch) Taper .............................................................................. ............................................................................................................ 0.005 mm (0.00019 inch) Out Of Round ............................................................................................................................................. ............................... 0.005 mm (0.00019 inch) Rod Bearing Journal: Diameter ........................................................................................................................................................ 50.758 - 50.784 mm (1.9983 - 1.9994 inch) Taper .............................................................................. ............................................................................................................ 0.005 mm (0.00019 inch) Out Of Round ............................................................................................................................................. ............................... 0.005 mm (0.00019 inch) Rod Side Clearance ................................................................................................................................................... 0.10 0.38 mm (0.0039 - 0.0149 inch) Crankshaft End Play ............................................................................................................................................ 0.0511 0.01780 mm (0.002 - 0.007 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications Crankshaft Balancer: Specifications Crankshaft Pulley Hub To Crankshaft Bolts .............................................................................................................................................. 105 Nm (77 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2233 Crankshaft Balancer: Service and Repair REMOVAL PROCEDURE ^ Tools Required J24420-B Crankshaft Pulley Hub Puller. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Raise the vehicle. 4. Remove the right front wheel and tire assembly. 5. Remove the engine splash shield. 6. Remove the crankshaft pulley bolts. 7. Remove the crankshaft pulley hub bolt. 8. Remove the crankshaft pulley. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2234 9. Remove the crankshaft pulley hub using J24420-B INSTALLATION PROCEDURE ^ Tools Required J29113 Crankshaft Pulley Hub Installer. 1. Coat the front cover seal contact area with engine oil. 2. Apply RTV sealer GM P/N 1052917 or equivalents to the keyway in the crankshaft. 3. Install the crankshaft pulley hub using J29113 NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Balancer <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 2235 4. Install the crankshaft pulley and bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 5. Install the crankshaft pulley hub bolt. ^ Tighten the bolt to 105 Nm (77 ft. lbs.). 6. Install the engine splash shield. 7. Install the right front wheel and tire assembly. 8. Lower the vehicle. 9. Install the drive belt. 10. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Clearance .................................................................................................................................................... 0.015 - 0.047 mm (0.0006 - 0.0018 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Specifications Piston Pin: Specifications Piston Pin: Diameter ........................................................................................................................................................ 20.320 - 20.325 mm (0.8000 - 0.8002 inch) Clearance In Piston ......................................................................................................................................... 0.008 0.0016 mm (0.0003 - 0.0006 inch) Interference Fin In Rod ................................................................................................................................... 0.025 - 0.045 mm (0.00098 - 0.0017 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring Compression: Top Groove Side Clearance ................................................................................................................................ 0.05 - 0.027 mm (0.0019 - 0.0011 inch) Second Groove Side Clearance ........................................................................................................................... 0.05 - 0.027 mm (0.0019 - 0.0011 inch) Top Ring Gap ............................................................................................................................................................ 0.25 - 0.50 mm (0.010 - 0.020 inch) Second Ring Gap ...................................................................................................................................................... 0.25 - 0.50 mm (0.010 - 0.020 inch) Piston Ring Oil: Groove Clearance ................................................................................................................................................ 0.05 0.021 mm (0.0019 - 0.0082 inch) Gap ................................................................................................. ........................................................................... 0.25 - 1.27 mm (0.010 - 0.050 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine uses hydraulic lifters and no valve lash adjustment is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications SERVICE SPECIFICATIONS Rocker Arm Ratio ................................................................................................................................ ......................................................................... 1.6 TORQUE SPECIFICATIONS Rocker Arm Bolts ................................................................................................................................. ................................................ 25 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2255 Rocker Arm Assembly: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Remove the valve rocker arm cover. IMPORTANT: Place the components in a rack in order of disassembly so they can be reinstalled at the same location and with the same mating surface as when removed. 3. Remove the rocker arm bolt. 4. Remove the rocker arm. 5. Remove the pushrod. INSTALLATION PROCEDURE IMPORTANT: Whenever new rocker arms and/or rocker arm balls are being installed, coat the bearing surfaces of the rocker arms and the rocker arm balls with camshaft assembly lube GM P/N 1052365 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2256 1. Install the pushrods, making sure that they seat in the lifters. 2. Install the rocker arms. 3. Apply Dri-Slide Moly lubricant GM P/N 1052948 or equivalent to the threads of the bolts. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the rocker arm bolts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 5. Install the valve rocker arm cover. 6. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption Valve Cover: Customer Interest Engine - Excessive Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-030A Date: May, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire 1998-2001 Chevrolet and GMC S Truck Models with 4 Cylinder 2.2L Engine (VINs 4, 5 - RPOs LN2, L43) This bulletin is being revised to correct the warranty information. Please discard Corporate Bulletin Number 01-06-01-030 (Section 06 - Engine/Propulsion System). Condition Some owners may comment on higher than expected engine oil consumption, therefore, having to add oil between oil changes. Important: For the LN2 and L43 engines, oil consumption greater than 1 quart (0.9 L) within 2000 miles (3200 km) is considered excessive. The oil consumption rate should be verified prior to repairs, as per Corporate Bulletin Number 01-06-01-011 dated March, 2001. Cause Two potential causes of high oil consumption have been identified: ^ The RTV seal between the stamped aluminum PCV baffle plate and the underside of the engine rocker cover may have deteriorated, allowing excessive oil mist to intrude into the PCV system. ^ The molded silicone intake manifold side gasket may have deteriorated at the PCV flow orifice, allowing excessive PCV gases to flow into the intake manifold. Correction Follow the guidelines listed under Oil Consumption Diagnosis in the Engine Mechanical section of the appropriate Service Manual, or in SI2000. If there are no other evident reasons for the concern (such as leaks), replace the rocker cover assembly with the new design cover, P/N 12570563, and replace the intake manifold side gasket with a new material gasket, P/N 12564499. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption > Page 2265 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption Valve Cover: Customer Interest Engine - Increased Oil Consumption File In Section: 6 - Engine Bulletin No.: 87-61-19 Date: March, 1998 Subject: Increased Oil Consumption (Replace Valve Rocker Arm Cover) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire 1998 Chevrolet and GMC S Models with 2.2L Engine (VIN 4 - RPO LN2) Built Prior to October 27, 1997 Condition Some customers may comment about increased oil consumption and having to add oil between oil changes. Cause On engines built before October 27, 1997, valve rocker arm cover baffle design may not be able to control oil flow into the foul air side of the crankcase ventilation system under certain conditions. In addition, during some high RPM operation of the engine, oil may be forced into the air cleaner duct and preplenum assembly. Correction Install a new rocker arm cover GM P/N 24577253 using procedures outlined in the appropriate Service Manual. Service Procedure 1. If the owner of the vehicle expresses concern with oil consumption, review the oil consumption rate and, if necessary, perform an oil consumption test on the vehicle. Perform an oil change, note the mileage and allow the owner to drive the vehicle for a sufficient number of miles for the engine to consume One Quart of oil. At the end of the test, review the oil consumption rate. Consumption of more than 1 quart (0.946L) within 2000 miles (3200 km) should be addressed. 2. Review the engine broadcast code label. The broadcast code label is located on the intake manifold on trucks and on the valve rocker arm cover on cars. Across the bottom of the label there will be a sequence of letters and numbers starting with the letter "T" The first five numbers in the sequence correspond to the engine build date starting with the calendar year; for example T 7 10 27 0001 = October 27, 1997. Any engine built on or after October 27, 1997, already has the revised cover in place and this bulletin does not apply. 3. Inspect the valve rocker arm cover for an identification mark (See Figure 1). The mark will be located on the rear (transmission) end of the valve rocker arm cover toward the intake manifold side of the engine. If the vehicle already has a valve rocker arm cover with this identification mark, DO NOT REPLACE THE VALVE ROCKER ARM COVER. If the vehicle has a concern with increased oil consumption, review the conditions listed in Step 5 of this bulletin and proceed with diagnostics in the engine section of the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption > Page 2270 Important: Always check engine oil on a level surface, be sure that the engine has been run until it has reached operating temperature and that the engine has been off for at least 5 minutes to allow for proper oil drain-down. If oil consumption is greater than that listed above, proceed with Step 4. 4. Install a revised valve rocker arm cover GM P/N 24577253 using procedures outlined in the Engine Mechanical Section of the appropriate Service Manual. 5. If the owner of the vehicle still has a concern with engine oil consumption after it has been determined that the latest design cover is installed. Perform further inspection of engine components for items that may cause increased oil consumption and repair as necessary. Possible causes of increased oil consumption include the following conditions: ^ External oil leaks ^ Incorrect oil level or improper reading of oil level indicator ^ Improper oil viscosity ^ Continuous high speed driving and/or severe usage such as towing, or driving in mountainous terrain ^ Blocked cylinder head, cylinder head gasket, or engine block oil drain holes ^ Valve guides and/or valve stem oil seals worn, or the seal omitted ^ Piston rings broken, improperly installed, missing, worn, or not seated properly ^ Pistons improperly installed or improperly fitted Parts Information Part Number Description 24577253 Cover, Valve Rocker Arm Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J0308 Cover and/or Gasket Rocker - Replace; 0.5 hr J Car J0308 Cover and/or Gasket Rocker - Replace; 0.8 hr S Truck Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption Valve Cover: All Technical Service Bulletins Engine - Excessive Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-030A Date: May, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire 1998-2001 Chevrolet and GMC S Truck Models with 4 Cylinder 2.2L Engine (VINs 4, 5 - RPOs LN2, L43) This bulletin is being revised to correct the warranty information. Please discard Corporate Bulletin Number 01-06-01-030 (Section 06 - Engine/Propulsion System). Condition Some owners may comment on higher than expected engine oil consumption, therefore, having to add oil between oil changes. Important: For the LN2 and L43 engines, oil consumption greater than 1 quart (0.9 L) within 2000 miles (3200 km) is considered excessive. The oil consumption rate should be verified prior to repairs, as per Corporate Bulletin Number 01-06-01-011 dated March, 2001. Cause Two potential causes of high oil consumption have been identified: ^ The RTV seal between the stamped aluminum PCV baffle plate and the underside of the engine rocker cover may have deteriorated, allowing excessive oil mist to intrude into the PCV system. ^ The molded silicone intake manifold side gasket may have deteriorated at the PCV flow orifice, allowing excessive PCV gases to flow into the intake manifold. Correction Follow the guidelines listed under Oil Consumption Diagnosis in the Engine Mechanical section of the appropriate Service Manual, or in SI2000. If there are no other evident reasons for the concern (such as leaks), replace the rocker cover assembly with the new design cover, P/N 12570563, and replace the intake manifold side gasket with a new material gasket, P/N 12564499. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption > Page 2276 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption Valve Cover: All Technical Service Bulletins Engine - Increased Oil Consumption File In Section: 6 - Engine Bulletin No.: 87-61-19 Date: March, 1998 Subject: Increased Oil Consumption (Replace Valve Rocker Arm Cover) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire 1998 Chevrolet and GMC S Models with 2.2L Engine (VIN 4 - RPO LN2) Built Prior to October 27, 1997 Condition Some customers may comment about increased oil consumption and having to add oil between oil changes. Cause On engines built before October 27, 1997, valve rocker arm cover baffle design may not be able to control oil flow into the foul air side of the crankcase ventilation system under certain conditions. In addition, during some high RPM operation of the engine, oil may be forced into the air cleaner duct and preplenum assembly. Correction Install a new rocker arm cover GM P/N 24577253 using procedures outlined in the appropriate Service Manual. Service Procedure 1. If the owner of the vehicle expresses concern with oil consumption, review the oil consumption rate and, if necessary, perform an oil consumption test on the vehicle. Perform an oil change, note the mileage and allow the owner to drive the vehicle for a sufficient number of miles for the engine to consume One Quart of oil. At the end of the test, review the oil consumption rate. Consumption of more than 1 quart (0.946L) within 2000 miles (3200 km) should be addressed. 2. Review the engine broadcast code label. The broadcast code label is located on the intake manifold on trucks and on the valve rocker arm cover on cars. Across the bottom of the label there will be a sequence of letters and numbers starting with the letter "T" The first five numbers in the sequence correspond to the engine build date starting with the calendar year; for example T 7 10 27 0001 = October 27, 1997. Any engine built on or after October 27, 1997, already has the revised cover in place and this bulletin does not apply. 3. Inspect the valve rocker arm cover for an identification mark (See Figure 1). The mark will be located on the rear (transmission) end of the valve rocker arm cover toward the intake manifold side of the engine. If the vehicle already has a valve rocker arm cover with this identification mark, DO NOT REPLACE THE VALVE ROCKER ARM COVER. If the vehicle has a concern with increased oil consumption, review the conditions listed in Step 5 of this bulletin and proceed with diagnostics in the engine section of the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption > Page 2281 Important: Always check engine oil on a level surface, be sure that the engine has been run until it has reached operating temperature and that the engine has been off for at least 5 minutes to allow for proper oil drain-down. If oil consumption is greater than that listed above, proceed with Step 4. 4. Install a revised valve rocker arm cover GM P/N 24577253 using procedures outlined in the Engine Mechanical Section of the appropriate Service Manual. 5. If the owner of the vehicle still has a concern with engine oil consumption after it has been determined that the latest design cover is installed. Perform further inspection of engine components for items that may cause increased oil consumption and repair as necessary. Possible causes of increased oil consumption include the following conditions: ^ External oil leaks ^ Incorrect oil level or improper reading of oil level indicator ^ Improper oil viscosity ^ Continuous high speed driving and/or severe usage such as towing, or driving in mountainous terrain ^ Blocked cylinder head, cylinder head gasket, or engine block oil drain holes ^ Valve guides and/or valve stem oil seals worn, or the seal omitted ^ Piston rings broken, improperly installed, missing, worn, or not seated properly ^ Pistons improperly installed or improperly fitted Parts Information Part Number Description 24577253 Cover, Valve Rocker Arm Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J0308 Cover and/or Gasket Rocker - Replace; 0.5 hr J Car J0308 Cover and/or Gasket Rocker - Replace; 0.8 hr S Truck Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 2282 Valve Cover: Specifications Rocker Arm Cover Bolts ...................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 2283 Valve Cover: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Remove the air cleaner outlet duct (1). 3. Remove the resonator. 4. Remove the resonator bracket. 5. Remove the valve rocker arm cover bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 2284 6. Remove the valve rocker arm cover. 7. Clean the sealing surface on the cylinder head and the valve rocker arm cover. INSTALLATION PROCEDURE 1. Install the valve rocker arm cover. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the valve rocker arm cover bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 3. Install the resonator bracket. 4. Install the resonator nuts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 2285 ^ Tighten the nuts to 25 Nm (18 ft. lbs.). 5. Install the resonator. 6. Install the air cleaner outlet duct (1). 7. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Inside Diameter .................................................................................................................................... 7.000 - 7.020 mm (0.275 - 0.276 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Width: Inlet ...................................................................................................................................................... ............................................ 2.80 mm (0.110 inch) Exhaust ................................................................ ............................................................................................................................ 3.51 mm (0.138 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair REMOVAL PROCEDURE ^ Tools Required J23590 Spark Plug Port Adapter - J5892-D Valve Spring Compressor CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the valve rocker arm cover. NOTICE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 3. Remove the spark plug. IMPORTANT: Whenever valve train components are removed for service, they should be kept in order. 4. Remove the rocker arm and pushrod on the cylinder to be serviced. Refer to Valve Rocker Arm and Push Rod Replacement. 5. Install J23590 in the spark plug port and apply compressed air to hold the valves in place. 6. Compress the valve spring with J5892-D and remove the valve locks and cap. 7. Carefully release the J5892-D. 8. Remove the spring, valve stem oil seal and the spring seat. INSTALLATION PROCEDURE ^ Tools Required J23590 Spark Plug Port Adapter Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2295 - J5892-D Valve Spring Compressor 1. Install the spring seat. 2. Install a new valve stem oil seal. 3. Set the valve spring and cap in place. 4. Compress the valve spring with J5892-D. IMPORTANT: Make sure that the valve locks seat properly in the upper groove of the valve stem. Grease may be used to hold the locks in place while releasing the compressor tool. 5. Install the valve locks and carefully release J5892-D 6. Remove J23590 NOTICE: Refer to Fastener Notice in Service Precautions. 7. Install the spark plug. ^ Tighten the spark plug to 15 Nm (11 ft. lbs.). 8. Install the rocker arm and the pushrod. Refer to Valve Rocker Arm and Push Rod Replacement. 9. Install the valve rocker arm cover. 10. Connect the negative battery cable. ^ Install the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Face Angle ................................................................................................................................ ............................................................................. 45° Valve Face Runout .............................................................................................................................. ............................................ 0.038 mm (0.0014 inch) Valve Margin: Exhaust ................................................................................................................................................ ...................... 2.13 - 1.87 mm (0.083 - 0.073 inch) Inlet ..................................................................... ...................................................................................................... 1.49 - 1.23 mm (0.058 - 0.048 inch) Valve Head Diameter: Inlet ...................................................................................................................................................... ................................................. 37 mm (1.45 inch) Exhaust ................................................................ ................................................................................................................................. 44 mm (1.73 inch) Valve Overall Length: Inlet ...................................................................................................................................................... .......................................... 134.23 mm (5.28 inch) Exhaust ................................................................ ............................................................................................................................... 127 mm (5.00 inch) Valve Stem To Guide Clearance: Inlet ...................................................................................................................................................... ............. 0.020 - 0.053 mm (0.0007 - 0.0020 inch) Exhaust .............................................................................................................................................................. 0.035 - 0.076 mm (0.0014 - 0.0029 inch) Valve Tip To Retainer Groove Centerline .................................................................................................................... 4.97 - 5.46 mm (0.195 0.214 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2304 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2305 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2306 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2307 Drive Belt: Specifications SERPENTINE BELT Belt tension is maintained by a spring tensioned idler pulley. No adjustment of the serpentine belt is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. IMPORTANT: Do not exceed 40 Nm (30 ft. lbs.) on the tensioner center bolt. 2. Rotate the belt tensioner clockwise. Use a 15 mm wrench. 3. Slide the belt from the generator pulley. 4. Release the tensioner. 5. If the vehicle has A/C remove the drive belt from the A/C compressor pulley. 6. Remove the drive belt. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2310 1. Route the drive belt. 2. If the vehicle has A/C route the drive belt around the A/C compressor pulley. 3. Rotate the belt tensioner clockwise. Use a 15 mm wrench. 4. Slide the belt onto the generator pulley. 5. Release the tensioner. NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Drive Belt Replacement > Page 2311 Drive Belt: Service and Repair Pump Drive Belt SERPENTINE BELT Vehicles equipped with a 2.2L engine have the power steering pump driven by a serpentine belt. The serpentine belt is self-adjusting within tensioner operating limits. For on-vehicle service of the serpentine belt, refer to ENGINE. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Serpentine Drive Belt Tensioner Bolt ....................................................................................................................................................... 50 Nm (37 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2315 Drive Belt Tensioner: Testing and Inspection ^ Tools Required J23600-B Belt Tension Gauge 1. Run the engine, with no accessories on, until the engine is warmed up. Shut the engine off and read the belt tension using the J23600-B placed halfway between the generator and the power steering pump. 2. Start the engine with the accessories off and allow the system to stabilize for 15 seconds. Turn the engine off. Using a 15 mm socket, apply clockwise force (tighten) to the tensioner pulley bolt. Release the force and immediately take a tension reading without disturbing belt tensioner position. 3. Using the same wrench, apply a counterclockwise force to the tensioner pulley bolt and raise the pulley to eliminate all tension. Slowly lower the pulley to the belt and take a tensioner reading without disturbing the belt tensioner position. 4. Average the three readings. If the average of the three readings is not between 133 - 222 Nm (30 - 50 lbs.) and the bolt is within the tensioners operating range, replace the tensioner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2316 Drive Belt Tensioner: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the drive belt. Refer to Drive Belt Replacement. 3. Remove the tensioner bolts. 4. Remove the tensioner. INSTALLATION PROCEDURE 1. Install the tensioner. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the tensioner bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the drive belt. Refer to Drive Belt Replacement. 4. Connect the negative battery cable. ^ Tighten the bolts to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Accessory Bracket Bolts ...................................................................................................................... ..................................................... 50 Nm (37 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Torque Strut > Component Information > Specifications Engine Torque Strut: Specifications Engine Mount Strut Bolt: Step 1 .................................................................................................................................................. ................................................ 100 Nm (74 ft. lbs.) Step 2 .................................................................. ......................................................................................................................... Turn An Additional 90° Engine Mount Strut Bracket Bolts: Rear ..................................................................................................................................................... ................................................. 75 Nm (55 ft. lbs.) Front ..................................................................... ................................................................................................................................ 66 Nm (49 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 01-06-01-004 > Jan > 01 > Idler Pulley - `Hoot/Whistle' Noise on Cold Start Up Idler Pulley: Customer Interest Idler Pulley - `Hoot/Whistle' Noise on Cold Start Up File In Section: 06 Engine/Propulsion System Bulletin No.: 01-06-01-004 Date: January, 2001 TECHNICAL Subject: Hoot/Whistling Noise At Start Up During Cold Ambient Temperature (Replace Idler Pulley Assembly) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire with 2.2 L Engine (VIN 4 - RPO LN2) Condition Some owners may comment on a loud "hoot" or whistling noise from the engine compartment during start up at cold ambient temperature of 0°C (32°F) or less. The noise would be of short duration, 5 seconds or less, and would not re-occur until the next cold ambient start up. This characteristic makes the condition difficult to diagnose in the dealership environment. Cause This condition may be caused by the bearing in the idler pulley. This condition will not occur when the engine is warm. A newly designed idler pulley is available from Service Parts Operations. The new pulley has a bearing with improved cold temperature performance characteristics. Correction Replace the idler pulley assembly. Refer to Service Information for replacement procedure. Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 01-06-01-004 > Jan > 01 > Idler Pulley - `Hoot/Whistle' Noise on Cold Start Up Idler Pulley: All Technical Service Bulletins Idler Pulley - `Hoot/Whistle' Noise on Cold Start Up File In Section: 06 Engine/Propulsion System Bulletin No.: 01-06-01-004 Date: January, 2001 TECHNICAL Subject: Hoot/Whistling Noise At Start Up During Cold Ambient Temperature (Replace Idler Pulley Assembly) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire with 2.2 L Engine (VIN 4 - RPO LN2) Condition Some owners may comment on a loud "hoot" or whistling noise from the engine compartment during start up at cold ambient temperature of 0°C (32°F) or less. The noise would be of short duration, 5 seconds or less, and would not re-occur until the next cold ambient start up. This characteristic makes the condition difficult to diagnose in the dealership environment. Cause This condition may be caused by the bearing in the idler pulley. This condition will not occur when the engine is warm. A newly designed idler pulley is available from Service Parts Operations. The new pulley has a bearing with improved cold temperature performance characteristics. Correction Replace the idler pulley assembly. Refer to Service Information for replacement procedure. Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 2337 Idler Pulley: Specifications Accessory Drive Belt Idler Pulley ............................................................................................................................................................ 50 Nm (37 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 2338 Idler Pulley: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Remove the idler pulley bolts. 4. Remove the idler pulley. INSTALLATION PROCEDURE 1. Install the idler pulley. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the idler pulley bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the drive belt. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure: At 65°C (150°F) ................................................................................................................................... ............................... 348 kPa (56 psi) @ 3000 rpm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair REMOVAL PROCEDURE 1. Remove the oil level indicator. 2. Remove the oil fill tube bolt. 3. Remove the oil fill tube. 4. Remove the oil fill tube seal. INSTALLATION PROCEDURE 1. Install the oil fill tube seal. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the oil fill tube and bolt. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 3. Install the oil level indicator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Engine Oil Drain Plug .......................................................................................................................... ...................................................... 25 Nm (18 ft lbs) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2353 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2354 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity Without Filter Change ........................................................................................................................................................... 3.473L (3.5 Qts.) When Changing the Oil Filter, Up To An Additional 0.473 Liter Or One Half Quart Of Oil May Be Needed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2357 Engine Oil: Fluid Type Specifications ENGINE OIL VISCOSITY All Temperatures ................................................................................................................................. ............................................ SAE 5W-30 (Preferred) Above 0°F (-18°C) ............................................ .............................................................................................................................................. SAE 10W-30 Using oils of any viscosity other than those viscosity's recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. The recommended oil viscosity for all vehicles when the temperature is above -18° C (0° F) is SAE 1OW-30. Engine oil viscosity (thickness) has an effect on the fuel economy and the cold-weather operation (starting and oil flow). Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather condition require higher viscosity engine oils for satisfactory lubrication. When the temperature will be very cold and never above 16° C (60° F), SAE 5W-30 should be used in all models. In areas of the world other than North America, it may be difficult to find oils that display the API STARBURST symbol and that are labeled as meeting the GM4718M Specification. If you cannot find API STARBURST displaying oils identified as meeting the GM4718M requirements, look for oils that meet the API Service SJ and ACEA A3-96 requirements. The recommended SAE engine oil viscosity is 5W-30, however, additional engine oil viscosities meeting the API Service SJ and ACEA A3-96 requirements may be used in accordance with the temperature ranges as shown in figure 3. NOTE: SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any vehicles at any time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2358 Engine Oil: Service Precautions Look for and use ONLY the engine oil that meet GM Specification. Oil that does not have the correct specification designation can cause engine damage not covered by the warranty. Do NOT use engine oil additives. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2359 Engine Oil: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan bolt. 4. Remove the oil filter. INSTALLATION PROCEDURE 1. Install the oil filter. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the oil pan drain bolt. ^ Tighten the oil pan drain bolt to 26 Nm (19 ft. lbs.). Lower the vehicle. 3. Fill the engine with oil to the appropriate mark. 4. Install negative battery cable. 5. Start engine and inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2364 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 17 Nm (13 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2365 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2366 Oil Filter: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan bolt. 4. Remove the oil filter. INSTALLATION PROCEDURE 1. Install the oil filter. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the oil pan drain bolt. ^ Tighten the oil pan drain bolt to 26 Nm (19 ft. lbs.). Lower the vehicle. 3. Fill the engine with oil to the appropriate mark. 4. Install negative battery cable. 5. Start engine and inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter .................................................................................................................................. ................................................... 35 Nm (26 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan ................................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2373 Oil Pan: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Remove the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the right front tire and wheel assembly. 4. Remove the right engine splash shield. 5. Drain the crankcase. 6. Remove the starter bracket at the block. 7. Remove the starter and lay it aside. Refer to Starter Motor Replacement. 8. Remove the transmission converter cover or the flywheel housing cover. 9. Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement. 10. Remove the oil pan bolts. 11. Remove the oil pan nuts. 12. Remove the oil pan. 13. Clean the sealing surfaces on the pan, cylinder case and front cover. Make sure that the old RTV is removed from the blind attaching holes. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2374 1. Place a 2-mm diameter bead of GM P/N 12346286 Loctite 5900 or equivalent to the oil pan sealing surface, except at the rear seal mounting surface. 2. Using a new oil pan rear seal, apply a thin coat of GM P/N 12346286 Loctite 5900 or equivalent on the ends down to the ears. 3. Install the oil pan. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 5. Install the oil pan nuts. ^ Tighten the nuts to 10 Nm (89 inch lbs.). 6. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement 7. Install the starter. Refer to Starter Motor Replacement in Engine Electrical. 8. Install the transmission converter cover or flywheel housing cover. 9. Install the right engine splash shield. 10. Install the right front tire and wheel assembly. 11. Lower the vehicle. 12. Fill the crankcase with engine oil. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2378 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2379 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2383 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolts .......................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure: At 65°C (150°F) ................................................................................................................................... ............................... 348 kPa (56 psi) @ 3000 rpm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque and Sequence Intake Manifold: Specifications Intake Manifold Torque and Sequence Tighten the bolts in sequence to 24 Nm (17 ft. lbs.). Tighten the throttle body to intake manifold bolts to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque and Sequence > Page 2397 Intake Manifold: Specifications Attaching Bolts 10 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2398 Intake Manifold: Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2399 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2400 Intake Manifold: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery cable. 3. Remove the air cleaner inlet duct (1). 4. Remove the resonator. 5. Remove the resonator bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2401 6. Remove the following cables: 9 The accelerator (2)-The cruise control (1) 7. Disconnect the vacuum hoses at the throttle body. 8. Remove the MAP sensor connector. 9. Remove the TP sensor connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2402 10. Remove the IAC connector. 11. Remove the two bolts attaching the accelerator bracket. 12. Remove the throttle body. 13. Remove the fuel feed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2403 14. Remove the fuel inlet pipe retainers. 15. Remove the intake manifold attaching nuts and the bolts. 16. Remove the intake manifold from the engine. 17. Clean the mating surfaces on the intake manifold and the cylinder head. 18. Inspect the manifold for cracks, broken flanges, and gasket surface damage. INSTALLATION PROCEDURE 1. Install the intake manifold assembly. 2. Install the intake manifold to cylinder head bolts and the nuts. NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2404 3. Install the fuel inlet pipe retainers. ^ Tighten the bolts to 24 Nm (18 inch lbs.). 4. Install the throttle body. 5. Connect the fuel feed and return quick-connect fittings. 6. Install the two bolts attaching the accelerator cable bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2405 7. Connect the MAP connector 8. Connect the TP sensor connector 9. Connect the IAC connector 10. Connect the vacuum hoses at the upper throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2406 11. Connect the following cables: ^ The accelerator (2). ^ The cruise control (1). 12. Install the resonator bracket. 13. Install the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2407 14. Install the air inlet duct assembly (1). 15. Install the fuel pump fuse. Inspect the fuel pump fuse for leaks. 16. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL PROCEDURE 1. Remove the Automatic Transmission. 2. Remove the flywheel. 3. Confirm the rear oil seal leak. IMPORTANT: Do not damage the crankshaft seal surface with the pry tool. 4. Remove the seal by inserting a screwdriver or similar tool in through the dust lip. Pry out the seal by moving the tool around the seal until the seal is removed. 5. Inspect the bore for nicks or burrs. Correct the bores as required. 6. Inspect the crankshaft for nicks or burrs on seal contact surface. Repair or replace the crankshaft as required. INSTALLATION PROCEDURE ^ Tools Required J34686 Rear Main Bearing Oil Seal Installer 1. Lubricate the seal bore to the seal surface with engine oil. 2. Install the new oil seal. Use the J34686 3. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Align the dowel pin of the tool with the dowel pin hole in the crankshaft. Attach the tool to the crankshaft. ^ Tighten the attaching screws to 3 - 7 Nm (27 - 62 inch lbs.). 5. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block. 6. Loosen the T-handle completely. 7. Remove the attaching screws and the tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2412 8. Ensure that the seal is seated squarely in the bore. 9. Install the flywheel. 10. Install the Automatic Transmission. 11. Start and run the engine. Inspect for oil leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL PROCEDURE 1. Remove the crankshaft pulley and the crankshaft pulley hub. Refer to Crankshaft Balancer and Hub Replacement 2. Remove the oil seal by prying it out with a large screwdriver. Do no damage the seal seat or the crankshaft. INSTALLATION PROCEDURE ^ Tools Required J35468 Seal Centering Tool. 1. Install the crankshaft pulley and the crankshaft pulley hub. Refer to Crankshaft Balancer and Hub Replacement. 2. Install the front cover oil seal using J35468. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption Intake Manifold Gasket: Customer Interest Engine - Excessive Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-030A Date: May, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire 1998-2001 Chevrolet and GMC S Truck Models with 4 Cylinder 2.2L Engine (VINs 4, 5 - RPOs LN2, L43) This bulletin is being revised to correct the warranty information. Please discard Corporate Bulletin Number 01-06-01-030 (Section 06 - Engine/Propulsion System). Condition Some owners may comment on higher than expected engine oil consumption, therefore, having to add oil between oil changes. Important: For the LN2 and L43 engines, oil consumption greater than 1 quart (0.9 L) within 2000 miles (3200 km) is considered excessive. The oil consumption rate should be verified prior to repairs, as per Corporate Bulletin Number 01-06-01-011 dated March, 2001. Cause Two potential causes of high oil consumption have been identified: ^ The RTV seal between the stamped aluminum PCV baffle plate and the underside of the engine rocker cover may have deteriorated, allowing excessive oil mist to intrude into the PCV system. ^ The molded silicone intake manifold side gasket may have deteriorated at the PCV flow orifice, allowing excessive PCV gases to flow into the intake manifold. Correction Follow the guidelines listed under Oil Consumption Diagnosis in the Engine Mechanical section of the appropriate Service Manual, or in SI2000. If there are no other evident reasons for the concern (such as leaks), replace the rocker cover assembly with the new design cover, P/N 12570563, and replace the intake manifold side gasket with a new material gasket, P/N 12564499. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption > Page 2424 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption Intake Manifold Gasket: All Technical Service Bulletins Engine - Excessive Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-030A Date: May, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire 1998-2001 Chevrolet and GMC S Truck Models with 4 Cylinder 2.2L Engine (VINs 4, 5 - RPOs LN2, L43) This bulletin is being revised to correct the warranty information. Please discard Corporate Bulletin Number 01-06-01-030 (Section 06 - Engine/Propulsion System). Condition Some owners may comment on higher than expected engine oil consumption, therefore, having to add oil between oil changes. Important: For the LN2 and L43 engines, oil consumption greater than 1 quart (0.9 L) within 2000 miles (3200 km) is considered excessive. The oil consumption rate should be verified prior to repairs, as per Corporate Bulletin Number 01-06-01-011 dated March, 2001. Cause Two potential causes of high oil consumption have been identified: ^ The RTV seal between the stamped aluminum PCV baffle plate and the underside of the engine rocker cover may have deteriorated, allowing excessive oil mist to intrude into the PCV system. ^ The molded silicone intake manifold side gasket may have deteriorated at the PCV flow orifice, allowing excessive PCV gases to flow into the intake manifold. Correction Follow the guidelines listed under Oil Consumption Diagnosis in the Engine Mechanical section of the appropriate Service Manual, or in SI2000. If there are no other evident reasons for the concern (such as leaks), replace the rocker cover assembly with the new design cover, P/N 12570563, and replace the intake manifold side gasket with a new material gasket, P/N 12564499. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 01-06-01-030A > May > 02 > Engine - Excessive Oil Consumption > Page 2430 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2435 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2436 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2440 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear Bolt Torque Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt Torque Camshaft Sprocket Bolt ....................................................................................................................... ................................................... 130 Nm (96 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear Bolt Torque > Page 2446 Camshaft Gear/Sprocket: Specifications Fastener Tightening Specifications Camshaft Sprocket .............................................................................................................................. .................................................... 130 Nm (96 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Pulley/Gear Torque Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley/Gear Torque Crankshaft Pulley Hub To Crankshaft Bolts .............................................................................................................................................. 105 Nm (77 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Pulley/Gear Torque > Page 2451 Crankshaft Gear/Sprocket: Specifications Crankshaft Gear/Hub Torque-Specifications Crankshaft Pulley Hub To Crankshaft Bolts .............................................................................................................................................. 105 Nm (77 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine Timing Chain: Service and Repair Interference Engine The OE manufacture does not specify if this engine is an interference engine or not. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2456 Timing Chain: Service and Repair Timing Chain and Sprocket REMOVAL PROCEDURE ^ Tools Required J22888-20 Crankshaft Sprocket Puller CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the crankcase front cover. Refer to Engine Front Cover Replacement. 3. Align the crankshaft sprocket and camshaft sprocket timing marks with the alignment tabs on the timing chain tensioner. IMPORTANT: Before removing the timing chain, measure the distance between the hole in the bracket and the unworn surface of the timing chain tensioner shoe. If the distance between the hole and the unworn surface of the timing chain tensioner shoe is more than 8 mm (0.314 inch), replace the tensioner, timing chain, and both sprockets. 4. Remove the timing chain tensioner bolts. 5. Remove the camshaft sprocket bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2457 6. Remove the camshaft sprocket and timing chain. 7. Remove the Torx (R) & bolt and the tensioner assembly. 8. Remove the crankshaft sprocket using J22888-20 INSTALLATION PROCEDURE ^ Tools Required J5590 Crankshaft Sprocket Installer 1. Install the crankshaft sprocket using J5590. Make sure that the crankshaft sprocket is seated against the crankshaft. 2. Install the timing chain and install the timing chain tensioner. 3. Compress the timing chain tensioner spring. 4. Insert a cotter pin or a nail into the hole in the tensioner to retain the timing chain tensioner shoe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2458 5. Install the timing chain tensioner. Do not tighten the timing chain tensioner bolts. 6. Align the crankshaft timing marks with the tab on the timing chain tensioner. 7. Align the camshaft timing mark with the tab on the timing chain tensioner. NOTICE: Refer to Fastener Notice in Service Precautions. 8. Install the camshaft sprocket and install the timing chain. ^ Tighten the timing chain tensioner bolts to 24 Nm (18 ft. lbs.). ^ Tighten the camshaft sprocket bolt to 130 Nm (96 ft. lbs.). 9. Remove the cotter pin or nail from the hole in the timing chain tensioner. 10. Install the crankcase front cover. Refer to Engine Front Cover Replacement. 11. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolts ............................................................................................................. ..................................................... 24 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Crankcase Front Cover Bolts .............................................................................................................. .................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2465 Timing Cover: Service and Repair REMOVAL PROCEDURE ^ Tools Required J2846.7-360 Engine Support Fixture CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Remove the drive belt tensioner. 4. Install the J28467-360 Engine Support Fixture. 5. Remove the engine mount assembly. Refer to Engine Mount Replacement. 6. Remove the generator rear brace. 7. Remove the generator. 8. Remove the power steering pump. Position the pump aside. Keep the lines attached. 9. Raise and support the vehicle. 10. Remove the oil pan. 11. Remove the crankshaft pulley and hub. 12. Remove the engine front cover bolts. 13. Remove the engine front cover. If necessary, carefully use a rubber mallet to loosen the cover. 14. Clean the sealing surface on the engine block. 15. Clean the sealing surface on the engine front cover. INSTALLATION PROCEDURE 1. Install the engine front cover gasket. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the engine front cover and the bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2466 ^ Tighten the bolts to 11 Nm (97 inch lbs.). 3. Install the crankshaft pulley and the crankshaft pulley hub. 4. Install the oil pan. Refer to Oil Pan Replacement. 5. Lower the vehicle. 6. Install the power steering pump. 7. Install the generator. 8. Install the generator rear brace. 9. Install the engine mount assembly. 10. Remove the J28467-360 Engine Support Fixture. 11. Install the drive belt tensioner. 12. Install the drive belt. 13. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 2472 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2473 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2474 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2475 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2476 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2477 Diagnostic Chart CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn OFF the in-tank fuel pump for 2 seconds after the ignition switch is turned ON or for 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. The unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION The number(s) below refer(s) to the step number(s) on the Diagnostic Table. 2. In order to relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gauge should be 284-325 kPa (41-47 psi). 3. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more of the following areas: ^ The fuel pump check valve ^ The fuel pump flex pipe ^ The valve or valve seat within the fuel pressure regulator ^ The fuel injector(s) 5. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or a misfire. You can use a scan tool in order to diagnose a lean condition. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. 8. When the engine is idling, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2478 the fuel pressure regulator. This will cause lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine turned OFF. 12. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition can cause a DTC P0132 or a DTC P0172 to set. Driveability conditions that are associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 13. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a malfunctioning fuel pressure regulator. 15. Fuel pressure being below 284 kPa (41 psi) can cause a lean condition. A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions that are associated with lean conditions can include hard starting (when the engine is cold), a hesitation, poor driveability, a lack of power, surging, and misfiring. 16. Restricting the fuel flow causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool in order to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gauge outlet hose is pinched. 22. Check the spark plug that is associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2494 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2500 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2501 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. Refer to Maintenance. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. Tighten the upper air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... ...................................................... 1.01 mm (.040 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2525 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ........................................................ 18 Nm (13 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2526 Spark Plug: Application and ID AC Type ............................................................................................................................................... ....................................................................... 41-928 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2527 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition Spark Plug: Service and Repair Conventional Ignition Description Description Removal Procedure 1. Turn the ignition key OFF. 2. Remove foreign material from around the spark plug holes. 3. Remove the wires from the plugs. 4. Remove the spark plug using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2 Install new plugs and tighten properly. 3. Reapply dielectric lubricant to the insulator boot. Tighten to 18 Nm (13 lb ft). 4. Reattach the boots to the plugs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition > Page 2530 Spark Plug: Service and Repair Integrated Direct Ignition Removal Procedure Tools Required J 36011 Spark Plug Connector Assembly Removal Tool 1. Remove the negative battery cable. 2. Remove the integrated Direct Ignition (IDI) assembly 4 bolts and connector. 3. Remove by pulling straight up on the housing. 4. Use the J 36011 to remove connector assembly(s) is stuck to the spark plugs. Use the tools by first twisting then pulling up on the connector assembly. 5. Remove the debris from the area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start the spark plugs into the cylinder head and tighten. Tighten the plugs to 18 Nm (13 lb ft). 3. Reinstall onto the IDI any spark plug boot connector assembly that stuck to a spark plug. ^ Check to be sure the spring terminal is inside the boot. ^ Reapply dielectric lubricant to the insulator boot. 4. Locate the IDI assembly over the spark plugs and push straight down. 5. Remove any loose lubricant that is present on the IDI assembly to cam housing bolts. IMPORTANT: Hand start the IDI assembly to cam housing bolts. 6. Apply threadlocker onto the IDI assembly to cam housing bolts. Tighten the bolts to 22 Nm (16 lb ft). 7. Install the electrical connector. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2534 Compression Check: Testing and Inspection ENGINE COMPRESSION TEST Perform the following steps in order to conduct a compression test for VIN 4: 1. Conduct the following steps in order to check cylinder compression: 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module. 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). IMPORTANT: The results of a compression test will fall into the following categories: ^ Normal-Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings-Compression low on first stroke. Tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. ^ Valves-Compression low on first stroke. Does not tend to build up on the following strokes. Does not improve much with addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine uses hydraulic lifters and no valve lash adjustment is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Fastener Tightening Specifications Water Pump: Specifications Fastener Tightening Specifications Water Pump ......................................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Water Pump Inlet ............................................. ......................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Fastener Tightening Specifications > Page 2542 Water Pump: Specifications Water Pump Pulley Water Pump Pulley Bolts ..................................................................................................................... ..................................................... 30 Nm (22 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2543 Water Pump: Service and Repair REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL(R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the cooling system. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Loosen the attaching bolts of the coolant pump pulley. 4. Remove the accessory drive belt. Refer to Drive Belt Replacement. 5. Remove the attaching bolts of the coolant pump pulley. 6. Remove the coolant pump pulley. 7. Remove the surge tank hose. 8. Remove the attaching bolts of the coolant pump. 9. Remove the coolant pump and the gasket. 10. Completely clean the sealing surfaces of the coolant pump and the engine block. INSTALLATION PROCEDURE NOTICE: Refer to Fastener Notice in Cautions and Notices. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2544 1. Using a new gasket, install the coolant pump and the attaching bolts. Coat the bolt threads with pipe sealant GM P/N 12346004, or equivalent. ^ Tighten the coolant pump bolts to 25 Nm (18 ft. lbs.). 2. Install the coolant pump pulley and the bolts. ^ Tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the accessory drive belt. Refer to Drive Belt Replacement. 4. Refill the cooling system. Refer to Draining and Filling Cooling System. 5. Connect the negative battery cable. 6. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. 7. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2550 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2551 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2552 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2553 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................ 10.0 Liters (10.5 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2556 Coolant: Fluid Type Specifications ENGINE COOLANT A 50/50 mixture of clean water (preferably distilled) and use only GM Goodwrench(R) DEX-COOL(R) or Havoline(R) DEX-COOL(R) (orange-colored, silicate-free) coolant, conforming to GM Specification 6277M. CAUTIONS: ^ The use of sealing pellets (or similar compounds) in the coolant system is NOT recommended.The use of sealing pellets may restrict the flow of coolant through the throttle body or other engine cooling system components. ^ If silicate coolant is added to the cooling system, premature engine, heater core or radiator corrosion may result. In addition, the coolant will require change SOONER, at 50 000 km (30,000 miles) or 24 months. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2557 Coolant: Description and Operation COOLANT DESCRIPTION NOTICE: When adding coolant, it is important that you use GM Goodwrench DEX-COOL or HAVOLINEO DEX-COOL coolant. If Coolant other than DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) is added to the system the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months. A 50/50 mixture of ethylene glycol (DEX-COOL (R) ) and water will provide the follow protection: NOTICE: Pure coolant can be added to raise the boiling point of the coolant, but too much will affect the freezing point. Do not use a solution stronger than 70 percent, as the freeze level rises rapidly after this point. Pure coolant will freeze at-22°C (-8°F). ^ Give freezing protection down to-37°C (-34°F). ^ Give boiling protection up to 129°C (260°F) ^ Help keep the proper engine temperature. ^ Let the warning lights and gauges work correctly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing Coolant: Testing and Inspection Coolant Concentration Testing Coolant testers J26568 Centigrade Scale or J23688 Fahrenheit Scale can be used to verify the antifreeze protection of the coolant. Verify that the refractometer markings are correct. Unless J26568 or J23688 has a provision for temperature correction, test the temperature at which testers are calibrated. IF the coolant is warmer or cooler the reading may be incorrect. Follow the manufacturer's directions on the tester being used. ^ Before each use, lift up the plastic cover at the slanted end of J26568 or J23688 exposing the measuring window and the bottom of the plastic cover. ^ Wipe the window with a tissue or a clean soft cloth. ^ Close the plastic cover. TESTING PROCEDURE ^ Tools Required J26568 or J23688 Coolant Tester Do not remove the clear plastic pump from the tester. 1. Release the tip of the pump from the coolant tester housing. 2. Insert the tip of the pump into the surge tank/radiator. The tip of the pump must be below the level of the coolant. 3. Press the bulb. Release the pump bulb in order to obtain a sample of the coolant. 4. Bend the tube around the J26568 or the J23688. Insert the tip of the pump into the cover plate opening. 5. Press the pump bulb. Allow a few drops to fall onto the measuring surface. Do not open the plastic cover when taking readings because any water evaporation will change the reading. 6. Point the coolant tester toward any light source. Look into the eyepiece. 6.1. The coolant protection reading is at the point where the dividing line between light and dark crosses the scale. Antifreeze protection is the scale on the right. 6.2. The temperature scale is reversed from a standard thermometer scale. 6.3. Below zero readings are on the upper half of the scale. 6.4. If the readings are not clear, properly clean and dry the measuring surface. Conduct a new test. Verify that enough fluid is on the measuring surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Coolant Concentration Testing > Page 2560 Coolant: Testing and Inspection Cooling System Leak Testing SURGE TANK CAP PRESSURE TEST ^ Tools Required J24460-01 Cooling System and Cap Pressure Tester - J24460-92 Cooling System Tester Adapter 1. Inspect the hose connections for leaks. 2. Inspect the surge tank cap for loss of pressure using the J24460-92 and the J24460-01.If the surge tank cap does not hold the rated pressure, replace the surge tank pressure cap. 3. Use the correct pressure cap. Use only a 103 kPa (15 psi) pressure cap. ON-VEHICLE PRESSURE TESTING PROCEDURE ^ Tools Required J24460-01 Cooling System and Cap Pressure Tester - J24460-92 Cooling System Tester Adapter 1. Inspect the connections of the coolant hoses for leaks. Repair as required. 2. Remove the surge tank cap. 3. Install J24460-01 to the surge tank. Follow the instructions supplied with the J24460-01. 4. Build up pressure to no more than 138 kPa (20 psi). 5. The system should hold the pressure for about two minutes. ^ If a measurable amount of pressure drops within two minutes, test for a leak. ^ If you find a leak, remove the radiator. Replace the radiator. Refer to Radiator Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Water Jacket Drain Plug ...................................................................................................................... ..................................................... 15 Nm (11 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2567 Engine Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Radiator Surge Tank Cap .................................................................................................................... .................................................... 4 Nm (35 inch lbs.) Surge Tank Inlet Hose Clip ............................. ...................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2571 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2572 Coolant Reservoir: Service and Repair REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL' coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the cooling system. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Disconnect the low coolant connector. 4. Remove the radiator surge tank bolt and tank. 5. Disconnect the low coolant switch connector from the surge tank. INSTALLATION PROCEDURE 1. Install the low coolant switch to the tank. NOTICE: Refer to Fastener Notice in Cautions and Notices. 2. Place the tank in the vehicle with a bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2573 3. Connect the coolant hoses to the radiator surge tank. 4. Connect the low coolant connector. 5. Fill the cooling system at the radiator surge tank. Refer to Draining and Filling Cooling System. 6. Connect the negative battery cable. 7. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Engine Cooling Fan Bolt ...................................................................................................................... ................................................... 6 Nm (53 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations Radiator Cooling Fan Motor: Component Locations Cooling Fan Location Cooling fan is located front of engine compartment. Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations > Page 2580 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Radiator Cooling Fan Motor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Coolant Fan Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 Radiator Cooling Fan Motor: Electrical Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2617 Radiator Cooling Fan Motor: Description and Operation ELECTRIC COOLING FAN CAUTION: If a fan blade is bent or damaged in any way, do not repair or reuse the damaged part Always replace a bent or damaged fan blade. Fan blades that have been damaged can not be assured of proper balance and could fail and fly apart during subsequent use. This creates an extremely dangerous situation. The fan blades must remain in proper balance. You cannot assure fan blade balance once a fan blade has been bent or damaged. A fan blade that is not in proper balance could fall and fly apart during use, creating an extremely dangerous situation. An electric engine cooling fan aids air flow through the radiator. An electric motor, attached to the radiator support, drives the fan. Coolant temperature activates the fan motor. If the vehicle is equipped with air conditioning, a switch can activate the fan motor when the compressor is operating. COOLING FAN OPERATION The Electronic Control Module (ECM) regulates the voltage to the cooling fan relay. The relay operates the fan when the engine coolant temperature exceeds 106°C (223°F) The cooling fan will turn on automatically during extended idle conditions under 5 miles per hour. For diagnosis and location of the relay, refer to Electrical Diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2618 Radiator Cooling Fan Motor: Service and Repair REMOVAL PROCEDURE IMPORTANT: Usually, electric cooling fan motors, fans, shrouds, and brackets are available separately. Always consult a parts catalog. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the wiring harness electrical connector from the motor and the fan frame. 3. Remove the fan assembly from the radiator support. CAUTION: If a fan blade is bent or damaged in any way, do not repair or reuse the damaged part. Always replace a bent or damaged fan blade. Fan blades that have been damaged can not be assured of proper balance and could fail and fly apart during subsequent use. This creates an extremely dangerous situation. The fan blades must remain in proper balance. You cannot assure fan blade balance once a fan blade has been bent or damaged. A fan blade that is not in proper balance could fail and fly apart during use, creating an extremely dangerous situation. 4. A fan blade that is not in proper balance could fail and fly apart during use, creating an extremely dangerous situation. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2619 1. Install the fan assembly to the radiator support. NOTICE: Refer to Fastener Notice in Cautions and Notices. 2. Connect the wiring harness ^ Tighten the bolt to 6 Nm (53 inch lbs.). 3. Connect the negative battery cable. ^ Tighten the negative battery cable bolt to 15 Nm (111 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAY Component Location Views The Cooling Fan Relay is located in the Underhood Fuse/Relay Center. The Underhood Fuse/Relay Center is located in the LH front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 2628 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2629 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2630 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2666 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2667 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2672 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2673 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2674 Heater Core: Specifications Heater Core Torque Specifications Heater Core Torque Specifications Heater Core Cover Screws 9 in.lb Heater Core Shroud Screws 9 in.lb Heater Core Strap Screws 9 in.lb Heater Outlet Screws 9 in.lb Heater Outlet Pipe Nut 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2675 Heater Core: Locations Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2676 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2677 Heater Core: Description and Operation The heater core transfers heat from the engine coolant to the incoming air. The heater core is located in the lower section of the heater module near the front of the dash. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2678 Heater Core: Service and Repair Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2679 (2 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Heater hoses from heater core. 4. Instrument Panel. 5. Heater core outlet. 6. Heater core cover. ^ There is a mounting screw located in a recess in the center of the cover 7. Heater core mounting clamps and beater core. Install or Connect 1. Heater core and heater core mounting clamps. Tighten ^ Screws to 1 Nm (9 lb in). 2. Heater core cover. Tighten ^ Screws to 1 Nm (9 lb in). 3. Heater core outlet. Tighten ^ Screws to 1 Nm (9 lb in). 4. Instrument Panel. 5. Heater hoses to heater core. 6. Fill cooling system and check for leaks. 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2680 Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission Whine at 2800-3200 RPM Heater Hose: Customer Interest Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission - Whine at 2800-3200 RPM Heater Hose: All Technical Service Bulletins Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2694 Heater Hose: Specifications Heater Hose and Pipe Torque Specifications Heater Hose and Pipe Torque Specifications Heater Outlet Screws 9 in.lb Heater Outlet Pipe Nut 18 ft.lb Heater Pipe Assembly to Engine Bolt and Nut 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2695 Heater Hose: Locations Heater Pipes The heater hoses are attached to the heater core at the front of dash and to the inlet and outlet pipes at the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2696 Heater Hose: Description and Operation The heater hoses and pipes carry engine coolant from the engine to the heater core. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Preliminary Instructions Heater Hose: Service and Repair Preliminary Instructions Heater Hoses Heater Pipes Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Make sure conduit and heat sleeving are in the same location as the original when replacing a hose. when servicing a heater hose with a quick connect assembly, REPLACEMENT OF THE RETAINER IS RECOMMENDED. Refer to Quick Connect Retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 2699 Heater Hose: Service and Repair Heater Hoses Heater Hoses Remove or Disconnect 1. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater hoses from heater pipes. 3. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Heater hoses to heater pipes. 3. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 2700 Heater Hose: Service and Repair Heater Pipe Assembly Heater Pipes Remove or Disconnect 1. Drain coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater core to pipe hoses from beater pipe assembly. 3. Heater pipe hose at coolant outlet on engine. 4. Heater pipe hose at coolant inlet on engine. 5. Bolt and nuts retaining pipe to engine. 6. Heater pipe assembly. Install or Connect 1. Heater pipe assembly. 2. Bolt and nuts retaining pipe to engine. Tighten ^ Bolt and nut to 25 N.m (18 lb ft). 3. Heater pipe hose to coolant inlet on engine. 4. Heater pipe hose to coolant outlet on engine. 5. Heater core to pipe hoses to heater pipe assembly. 6. Refill coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. 1. Drain the coolant from the radiator. Refer to Draining and Filling Cooling System. 2. Turn the draincock counter clockwise to an intermediate position. 3. Remove the radiator drain stem and seal. The seal usually comes out attached to the stem. 4. Clean the drain. INSTALLATION PROCEDURE 1. Install the seal on the drain cock stem. 2. Install the drain cock. Turn the stem clockwise to lock. 3. Refill the coolant to the proper level. Refer to Draining and Filling Cooling System. 4. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Technical Service Bulletins > Cooling - Upper Radiator Hose Replacement Radiator Hose: Technical Service Bulletins Cooling - Upper Radiator Hose Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-015 Date: October, 1999 INFORMATION Subject: Upper Radiator Hose Replacement Models: 1998-2000 Chevrolet Cavalier 1998-2000 Pontiac Sunfire with 2.2L, L-4 Engine (VIN 4 RPO LN2) When replacing the upper radiator hose, be sure to install protective conduit, P/N 22618378. Position the conduit to protect the hose from contact (2) with the battery tray (1), 21 mm (8 1⁄4 in) with the seam of the conduit facing away from the battery tray. Parts Information Part Number Description 22618378 Conduit Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) Radiator Hose: Service and Repair Radiator Hose Replacement (Inlet) REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. It silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant to a level below the hose being removed. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the radiator inlet hose and the clamps from the radiator and the coolant outlet. 4. Disconnect the radiator outlet hose and the clamps from the following places: ^ The radiator ^ The coolant pump ^ The radiator surge tank 5. Remove the radiator outlet hose. INSTALLATION PROCEDURE NOTICE: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. 1. Install the radiator outlet hose and the clamps to the following places: ^ The radiator ^ The coolant pump ^ The radiator surge tank 2. Install the radiator inlet hose and the clamp to the radiator and the coolant outlet. NOTICE: Refer to Fastener Notice in Cautions and Notices. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2711 3. Connect the negative battery cable. ^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.). 4. Refill the coolant. Refer to Draining and Filling Cooling System. 5. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2712 Radiator Hose: Service and Repair Radiator Hose Replacement (Outlet) REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant to a level below the hose that is being removed. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the radiator inlet hose (3) and the clamps (2) from the radiator and the coolant outlet (1). 4. Disconnect the radiator outlet hose (1) and the clamps (2) from the following places: ^ The radiator ^ The radiator outlet pipe (3) ^ The radiator surge tank 5. Remove the radiator outlet hose. INSTALLATION PROCEDURE NOTICE: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2713 1. Install the radiator outlet hose (3) and the clamps (2) to the following places: ^ The radiator ^ The radiator outlet pipe (3) ^ The radiator surge tank 2. Install the radiator inlet hose (3) and the clamps (2) to the coolant outlet (1) and the radiator. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Connect the negative battery cable. ^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.). 4. Refill the coolant. Refer to Draining and Filling Cooling System. 5. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2714 Radiator Hose: Service and Repair Radiator Pipe Replacement - Outlet REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the exhaust manifold heat shield. 4. Remove the cover to the outlet pipe bolt through the exhaust manifold runners. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Disconnect the radiator outlet hose (1) from the radiator outlet pipe (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2715 7. Remove the radiator outlet pipe (1) to the oil pan (2) bolt (3). 8. Remove the cover to the outlet pipe bolt. 9. Remove the thermostat (2). 10. Clean the mating surfaces of the radiator outlet pipe and the coolant pump cover. INSTALLATION PROCEDURE 1. Install the thermostat (2). NOTICE: Refer to Fastener Notice in Cautions and Notices. 2. Install the cover to the outlet pipe bolt ^ Tighten the bolt to 14 Nm (124 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement (Inlet) > Page 2716 3. Install the radiator outlet pipe (1) to oil pan (2). ^ Tighten the outlet pipe to oil pan bolt to 26 Nm (19 ft. lbs.). 4. Connect the radiator hose (1) to the outlet pipe (3). 5. Lower the vehicle. 6. Install the cover to the outlet pipe bolt through the exhaust manifold runners. 7. Install the manifold heat shield. 8. Fill the cooling system. Refer to Draining and Filling Cooling System. 9. Connect the negative battery cable. 10. Inspect for leaks. 11. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations COOLING FAN RELAY Component Location Views The Cooling Fan Relay is located in the Underhood Fuse/Relay Center. The Underhood Fuse/Relay Center is located in the LH front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2725 Engine Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 2731 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2732 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2733 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2736 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2740 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2741 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2742 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2743 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2754 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2755 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2769 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2770 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature 82 Degrees C 180 Degrees F Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2774 Thermostat: Description and Operation THERMOSTAT DESCRIPTION The 2.2L (4 cyl.) and 2.4L (4 cyl.) engines use a wax pellet-type thermostat. The thermostat is in the coolant inlet passage. The thermostat does the following functions: ^ Controls the flow of coolant ^ Provides fast engine warm-up ^ Regulates the coolant temperature A wax pellet, or power element, (4) in the thermostat expands when heated, and contracts when cooled. The pellet element connects through a piston (1) to a valve (2). When the pellet element is heated, pressure is exerted against a rubber diaphragm (3) which forces the valve to open. As the element is cooled, the contraction allows a spring (5) to close the valve. While the coolant is cold, the valve remains closed. This prevents circulation of coolant through the radiator. At this point, coolant is only allowed to circulate through the engine in order to quickly warm the engine. As the engine warms, the pellet element expands and the thermostat valve opens. This permits coolant to flow through the radiator, where the heat is dissipated through the radiator walls. This opening and closing of the thermostat permits enough coolant to enter the radiator in order to keep the engine within specified temperature limits. Both engines use a 82°C (180°F) thermostat. Do not use a thermostat rated above these control temperatures. A higher-temperature thermostat does not offer a faster warm-up, because the valve (1) remains tightly closed until the thermostat reaches the control temperature. This is much like a lower-temperature thermostat. Always install the thermostat with the pointed end facing the radiator. Incorrect installation could cause the engine to overheat. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2775 Thermostat: Testing and Inspection Part 1 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2776 Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2777 Thermostat: Service and Repair REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL (R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the coolant to level below the thermostat. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Remove the radiator coolant outlet pipe attaching bolts. 4. Remove the coolant outlet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2778 5. Remove the thermostat. 6. Clean the mating surfaces of the radiator outlet and the radiator outlet pipe. INSTALLATION PROCEDURE 1. Install the thermostat. 2. Install the coolant outlet. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Install the coolant outlet attaching bolts. Tighten Tighten the coolant outlet bolts to 14 N.m (124 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2779 4. Refill the engine coolant. Refer to Draining and Filling Cooling System. 5. Connect the negative battery cable. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Fastener Tightening Specifications Water Pump: Specifications Fastener Tightening Specifications Water Pump ......................................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Water Pump Inlet ............................................. ......................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Fastener Tightening Specifications > Page 2784 Water Pump: Specifications Water Pump Pulley Water Pump Pulley Bolts ..................................................................................................................... ..................................................... 30 Nm (22 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2785 Water Pump: Service and Repair REMOVAL PROCEDURE NOTICE: When adding coolant, use DEX-COOL(R) coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50,000 km (30,000 mi) or 24 months. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Drain the cooling system. Recover the coolant. Refer to Draining and Filling Cooling System. 3. Loosen the attaching bolts of the coolant pump pulley. 4. Remove the accessory drive belt. Refer to Drive Belt Replacement. 5. Remove the attaching bolts of the coolant pump pulley. 6. Remove the coolant pump pulley. 7. Remove the surge tank hose. 8. Remove the attaching bolts of the coolant pump. 9. Remove the coolant pump and the gasket. 10. Completely clean the sealing surfaces of the coolant pump and the engine block. INSTALLATION PROCEDURE NOTICE: Refer to Fastener Notice in Cautions and Notices. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2786 1. Using a new gasket, install the coolant pump and the attaching bolts. Coat the bolt threads with pipe sealant GM P/N 12346004, or equivalent. ^ Tighten the coolant pump bolts to 25 Nm (18 ft. lbs.). 2. Install the coolant pump pulley and the bolts. ^ Tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the accessory drive belt. Refer to Drive Belt Replacement. 4. Refill the cooling system. Refer to Draining and Filling Cooling System. 5. Connect the negative battery cable. 6. Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks. 7. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts ......................................................................................................................... ............................................... 13 Nm (115 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement Exhaust Manifold: Service and Repair Exhaust Manifold Replacement REMOVAL PROCEDURE CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped with OnStar (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar module). Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar module in any way while the ignition is On or with RAP activated may cause activation of the OnStar Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced. 1. Disconnect the negative battery cable. 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System. 3. Remove the oxygen sensor lead. 4. Remove the drive belt. Refer to Drive Belt Replacement. 5. Remove the generator rear brace. 6. Remove the generator. Refer to Generator Replacement. 7. Remove the radiator inlet pipe. 8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 9. Remove the exhaust pipe to the exhaust manifold. 10. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement > Page 2796 11. Remove the oil fill tube. Refer to Oil Level Indicator and Tube Replacement. 12. Remove the heater outlet hose assembly nut from the exhaust manifold. 13. Remove the exhaust manifold nuts. 14. Remove the exhaust manifold and the gasket. 15. Clean the mating surfaces at the cylinder head and the exhaust manifold. 16. Inspect the manifold for cracks, broken flanges and gasket surface damage. 17. Verify the alignment of the exhaust manifold mating surfaces. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced. INSTALLATION PROCEDURE 1. Install the exhaust manifold gasket. 2. Install the exhaust manifold. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the exhaust manifold nuts. Tighten Tighten the nuts to 13 Nm (115 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement > Page 2797 4. Install the heater outlet hose assembly nut. Tighten ^Tighten the nut to 25 Nm (18 ft. lbs.). 5. Install the oil fill tube. Refer to Oil Level Indicator and Tube Replacement. 6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 7. Install the exhaust pipe to the manifold. Refer to Intermediate Pipe Replacement. 8. Lower the vehicle. 9. Install the radiator inlet pipe. 10. Install the generator. Refer to Generator Replacement. 11. Install the generator rear brace. 12. Install the drive belt. Refer to Drive Belt Replacement. 13. Install the oxygen sensor lead. 14. Connect the negative battery cable. Tighten ^ Tighten the bolt to 16 Nm (12 ft. lbs.). 15. Refill the cooling system, Refer to Draining and Filling Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement > Page 2798 Exhaust Manifold: Service and Repair Exhaust Manifold Pipe Replacement REMOVAL PROCEDURE NOTICE: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position. 1. Raise and suitably support the vehicle. 2. Support the three-way catalytic converter. 3. Remove the exhaust manifold pipe assembly from the three-way catalytic converter. 4. Remove the exhaust manifold pipe assembly from the exhaust manifold. 5. Remove the exhaust manifold seal and the three-way catalytic converter seal. 6. Clean the flange surfaces. INSTALLATION PROCEDURE 1. Install the exhaust manifold seal and the three-way catalytic converter seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement > Page 2799 2. Install the exhaust manifold pipe assembly to the exhaust manifold. 3. Install the exhaust manifold pipe assembly to the three-way catalytic converter. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe To Manifold Nut ............................................................................................................. .................................................... 45 Nm (33 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2803 Exhaust Pipe: Service and Repair REMOVAL PROCEDURE NOTICE: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. IMPORTANT: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Support the three-way catalytic converter. 3. Cut the intermediate pipe at the muffler. 4. Remove the intermediate pipe from the three-way catalytic converter. 5. Remove the intermediate pipe from the hanger. 6. Remove the intermediate pipe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2804 7. Remove the muffler from the hangers. 8. Remove the three-way catalytic converter seals. 9. Clean the flange surface. INSTALLATION PROCEDURE 1. Install the three-way catalytic converter seals. 2. Install the intermediate pipe to the hanger. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2805 3. Install the intermediate pipe to the three-way-catalytic converter. 4. Install the muffler to the hangers. 5. Weld the muffler to the intermediate pipe. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger To Frame .................................................................................................................... .................................................... 16 Nm (12 ft. lbs.) Muffler Hanger To Muffler Bolt .............................................................................................................................................................. 16 Nm (12 ft. lbs.) Muffler Strap .......................................................................................................... .................................................................................. 16 Nm (12 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 83-66-01 > Mar > 98 > Muffler - Thumping Noise in Park or Drive Muffler: Customer Interest Muffler - Thumping Noise in Park or Drive File In Section: 6 - Engine Bulletin No.: 83-66-01 Date: March, 1998 Subject: Thumping Noise from the Muffler Can Be Heard at Idle in Park or Drive (Replace Muffler) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment that a thumping or oil canning noise may be heard on cold or hot exhaust systems. This noise can be heard while at idle in park or drive. Cause Condition may be caused by noise produced by the outer and inner muffler shells separating from different thermal expansion rates. The outer shell usually will buckle in the rear chamber of the muffler. Pressure pulsation from the engine causes the outer shell to resonate and produce the thumping noise. Important: Mufflers built after October, 1997 have an additional twelve spot welds added to prevent this condition. Correction Replace the muffler with P/N 22614984 (Chevrolet) and P/N 22614985 (Pontiac). Parts Information P/N Description 22614984 (Chevrolet) Muffler Assembly 22614985 (Pontiac) Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time L2584 Muffler - Replace Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Muffler: Customer Interest Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 2821 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 83-66-01 > Mar > 98 > Muffler - Thumping Noise in Park or Drive Muffler: All Technical Service Bulletins Muffler - Thumping Noise in Park or Drive File In Section: 6 - Engine Bulletin No.: 83-66-01 Date: March, 1998 Subject: Thumping Noise from the Muffler Can Be Heard at Idle in Park or Drive (Replace Muffler) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment that a thumping or oil canning noise may be heard on cold or hot exhaust systems. This noise can be heard while at idle in park or drive. Cause Condition may be caused by noise produced by the outer and inner muffler shells separating from different thermal expansion rates. The outer shell usually will buckle in the rear chamber of the muffler. Pressure pulsation from the engine causes the outer shell to resonate and produce the thumping noise. Important: Mufflers built after October, 1997 have an additional twelve spot welds added to prevent this condition. Correction Replace the muffler with P/N 22614984 (Chevrolet) and P/N 22614985 (Pontiac). Parts Information P/N Description 22614984 (Chevrolet) Muffler Assembly 22614985 (Pontiac) Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time L2584 Muffler - Replace Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Muffler: All Technical Service Bulletins Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 2831 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2832 Muffler: Service and Repair REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Cut the intermediate pipe at the muffler near the weld. 3. Remove the muffler from the hangers. INSTALLATION PROCEDURE 1. Install the muffler to the hangers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2833 2. Weld the muffler to the intermediate pipe. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Resonator: > 63-66-04C > Sep > 98 > Exhaust Metallic Noise or Rap Heard on Cold Exhaust Exhaust Resonator: Customer Interest Exhaust - Metallic Noise or Rap Heard on Cold Exhaust File In Section: 6 - Engine Bulletin No.: 63-66-04C Date: September, 1998 Subject: Metallic Noise or "Cold Rap" Heard on Cold Exhaust Systems During Free Rev or Engine Load (Install Resonator Assembly) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) This bulletin is being revised to change labor time information. Please discard Corporate Bulletin Number 63-66-04B (Section 6 - Engine). Condition Some owners may comment that a metallic noise or "cold rap" may be heard on cold exhaust systems. Condition occurs prior to muffler inlet gasses exceeding 400°F (204°C) and is found at 2800 rpms during free rev or engine load. Cause The resonator frequencies, in combination with ambient conditions and exhaust tuning, may create the "cold rap" condition. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Resonator: > 63-66-04C > Sep > 98 > Exhaust Metallic Noise or Rap Heard on Cold Exhaust > Page 2842 A resonator assembly (Figure 1) is available to correct this condition. Install resonator assembly (P/N 22610121) to current exhaust pipe just behind the catalytic converter. Attach by cutting exhaust pipe 381 mm (15 in.) behind front exhaust pipe flange. Slip expanded pipe of assembly over existing pipe. REPLACE GASKET (P/N 22545048). Attach resonator assembly to flange of converter with three bolts. Torque bolts to 30 N.m (22 lb ft). Attach pipe with U-clamp. Align resonator assembly in tunnel area. Verify 20 mm (0.8 in.) clearance to heat shield. Tighten U-clamp to 30 N.m (22 lb ft). Parts Information P/N Description 22610121 Resonator Assembly 22545048 Gasket Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time L2720 0.4 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Resonator: > 63-66-04C > Sep > 98 > Exhaust - Metallic Noise or Rap Heard on Cold Exhaust Exhaust Resonator: All Technical Service Bulletins Exhaust - Metallic Noise or Rap Heard on Cold Exhaust File In Section: 6 - Engine Bulletin No.: 63-66-04C Date: September, 1998 Subject: Metallic Noise or "Cold Rap" Heard on Cold Exhaust Systems During Free Rev or Engine Load (Install Resonator Assembly) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) This bulletin is being revised to change labor time information. Please discard Corporate Bulletin Number 63-66-04B (Section 6 - Engine). Condition Some owners may comment that a metallic noise or "cold rap" may be heard on cold exhaust systems. Condition occurs prior to muffler inlet gasses exceeding 400°F (204°C) and is found at 2800 rpms during free rev or engine load. Cause The resonator frequencies, in combination with ambient conditions and exhaust tuning, may create the "cold rap" condition. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Resonator: > 63-66-04C > Sep > 98 > Exhaust - Metallic Noise or Rap Heard on Cold Exhaust > Page 2848 A resonator assembly (Figure 1) is available to correct this condition. Install resonator assembly (P/N 22610121) to current exhaust pipe just behind the catalytic converter. Attach by cutting exhaust pipe 381 mm (15 in.) behind front exhaust pipe flange. Slip expanded pipe of assembly over existing pipe. REPLACE GASKET (P/N 22545048). Attach resonator assembly to flange of converter with three bolts. Torque bolts to 30 N.m (22 lb ft). Attach pipe with U-clamp. Align resonator assembly in tunnel area. Verify 20 mm (0.8 in.) clearance to heat shield. Tighten U-clamp to 30 N.m (22 lb ft). Parts Information P/N Description 22610121 Resonator Assembly 22545048 Gasket Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time L2720 0.4 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2860 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2861 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2862 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2863 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2864 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2870 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2875 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2876 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2877 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2878 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 2879 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 2889 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2894 Powertrain Control Module: Specifications PCM Retainer Bolts 6-9 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2895 Powertrain Control Module: Locations Location View At the right front corner, behind the fascia Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Powertrain Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2916 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2917 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Powertrain Control Module: Connector Views Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2933 Powertrain Control Module: Description and Operation Description The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control Control Module Function The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure Powertrain Control Module: Service and Repair Password Learn Procedure In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the PC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 2936 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) Replacement/Programming Repair Instructions NOTICE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. REMOVAL PROCEDURE IMPORTANT: Turn the ignition switch OFF to prevent internal PCM damage when disconnecting or reconnecting power to the PCM (for example, battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). The ignition switch should be OFF for at least 10 seconds before disconnecting the power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and the horn. NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 5. Disconnect the PCM electrical connectors (1). 6. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 2937 7. Slide the PCM and the retainer (1) from the PCM bracket (2). 8. Remove the retainer (1) from the PCM (2). INSTALLATION PROCEDURE Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the malfunctioning PCM. 1. Slide the PCM (2) into the PCM retainer (1). 2. Slide the PCM and the retainer (1) into the PCM bracket (2) slots. 3. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb ft). NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 4. Connect the PCM electrical connectors (1). 5. Install the horn and the horn attaching bolt. 6. Connect the horn electrical connector. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. 9. Reprogram the PCM and perform the Crankshaft Position System Variation Learning Procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Knock Sensor Module > Component Information > Description and Operation Knock Sensor Module: Description and Operation The KS module is an integral part of the PCM. The KS module is not serviceable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2977 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL PROCEDURE 1. Remove the relay center cover. 2. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Cover Bolts 16 ft.lb Screws 35 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 2982 Ignition Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 2983 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 2984 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 Ignition Control Module (C1) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 > Page 2987 Ignition Control Module (C2) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 2988 Ignition Control Module: Description and Operation This system uses the same circuits between the ICM and the PCM that distributor type systems use. Following is a brief description for each of the IC circuits. Crankshaft Position (CKP) Sensor Activity (7X reference) - The CKP sensor generates a signal to the ICM which results in a reference pulse (square wave signal) being sent to the PCM. The PCM uses this signal to calculate crankshaft position, engine speed and injector pulse width. The engine will not start or run if this circuit is open or grounded. Reference Low - This wire is grounded through the ICM and insures that the ground circuit has no voltage drop between the ICM and the PCM which could affect performance. The PCM compares voltage pulses on the 7X or reference input to those on this circuit, ignoring any pulses that appear on both. A pulse that appears on the reference low circuit alone is assumed to be caused by Radio Frequency Interference (RFI). Ignition Control (IC) 1 & 2 - The PCM sends the ignition control pulse to the ICM on these circuits. These signals are similar to the 7X reference pulse square wave except that the PCM uses sensor inputs to determine the pulse timing to control spark advance. When the PCM receives the 7X signal, it will determine which pair of cylinders will be fired (1 & 4 or 2 & 3). It then tells the ICM which cylinder to fire through the ignition control circuits. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 2989 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the ignition coils from the module (1). 4. Remove the module from the assembly plate. INSTALLATION PROCEDURE 1. Install the module to the assembly plate 2. Install the ignition coils. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3030 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3031 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3032 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3064 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3065 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3066 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3067 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3068 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3069 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 3074 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3075 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3076 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3079 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3080 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3081 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3082 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3083 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3084 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3085 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3086 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3087 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3088 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3089 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3090 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3091 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3092 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3093 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3094 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3095 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3096 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3112 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3113 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3117 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3118 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3119 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3155 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3158 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3163 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3164 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3165 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3166 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3167 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3168 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 3169 Fuel Level Sensor: Description and Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gauge. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 3170 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Fuel level sensor (1) to the modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill the fuel tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition to the ON position for two seconds. 7.2. Turn the ignition to the OFF position for ten seconds. 7.3. Turn the ignition to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Intake Air Temperature (IAT) Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3178 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3179 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3180 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3193 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3194 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3195 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3196 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3197 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3198 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3199 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3200 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3216 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the ECT sensor. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the IAT sensor through a resistor in the PCM and monitors the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3217 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the IAT sensor into the air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3221 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3222 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3223 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3224 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3259 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3260 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure (MAP) Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 3264 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 3300 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gauge. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 3301 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the throttle body. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold (2). INSTALLATION PROCEDURE 1. Install the MAP sensor (1) to the intake manifold (2). 2. Connect the MAP sensor electrical connector. 3. Install the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3305 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 41 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor Oxygen Sensor: Locations Post Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3311 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3312 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3313 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3314 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3315 Oxygen Sensor: Locations Pre-Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3316 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 3317 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 Post Converter Heated Oxygen Sensor (HO2S 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 Oxygen Sensor: Description and Operation Oxygen Sensor 1 The Oxygen Sensor (O2S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). This voltage can be measured with a scan tool. By monitoring the voltage output of the O2S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low O2S 1 voltage = rich command - Rich mixture-high O2S 1 voltage = lean command The O2S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See the DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 > Page 3355 Oxygen Sensor: Description and Operation Rear Heated Oxygen Sensor The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 Oxygen Sensor: Service and Repair Oxygen Sensor 1 REMOVAL PROCEDURE NOTICE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail of connector could affect proper operation of the oxygen sensor. IMPORTANT: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the O2S 1. IMPORTANT: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). 1. Turn the ignition switch OFF 2. Disconnect the Oxygen Sensor 1 electrical connector. IMPORTANT: Do not use excessive force when removing the 02S sensor. 3. Carefully remove the Oxygen Sensor 1. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads to the oxygen sensor with anti-seize compound, if necessary. 2. Install the Oxygen Sensor 1. Tighten the 02S 1 41 Nm (30 lb ft). 3. Connect the Oxygen Sensor 1 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 > Page 3358 Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 REMOVAL PROCEDURE NOTICE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. IMPORTANT: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the 02S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. NOTICE: The use of excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb ft). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3362 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3363 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3370 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3399 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3400 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3401 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3410 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3411 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3417 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3418 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3419 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3420 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 3423 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3424 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3425 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3430 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3431 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3432 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3433 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Vehicle Speed Sensor (VSS) (3T40) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3469 Vehicle Speed Sensor: Description and Operation The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Transmission for more information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3509 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3510 Fuel Pressure Sensor/Switch: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the system fuel pressure. 3. Drain fuel tank. 4. Remove the fuel tank. 5. Remove the electrical connector from the fuel tank pressure sensor. 6. Remove the fuel tank pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3514 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3515 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3551 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3552 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3553 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3558 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3559 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3560 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3596 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3597 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3601 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3602 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3603 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3639 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3642 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3651 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3652 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3653 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3654 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3667 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3668 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3669 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3670 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3671 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3672 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3673 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3689 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3690 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 3696 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3697 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3698 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3699 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3700 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3701 Diagnostic Chart CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn OFF the in-tank fuel pump for 2 seconds after the ignition switch is turned ON or for 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. The unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION The number(s) below refer(s) to the step number(s) on the Diagnostic Table. 2. In order to relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gauge should be 284-325 kPa (41-47 psi). 3. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more of the following areas: ^ The fuel pump check valve ^ The fuel pump flex pipe ^ The valve or valve seat within the fuel pressure regulator ^ The fuel injector(s) 5. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or a misfire. You can use a scan tool in order to diagnose a lean condition. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. 8. When the engine is idling, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3702 the fuel pressure regulator. This will cause lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine turned OFF. 12. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition can cause a DTC P0132 or a DTC P0172 to set. Driveability conditions that are associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 13. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a malfunctioning fuel pressure regulator. 15. Fuel pressure being below 284 kPa (41 psi) can cause a lean condition. A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions that are associated with lean conditions can include hard starting (when the engine is cold), a hesitation, poor driveability, a lack of power, surging, and misfiring. 16. Restricting the fuel flow causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool in order to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gauge outlet hose is pinched. 22. Check the spark plug that is associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3718 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3724 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3725 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. Refer to Maintenance. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. Tighten the upper air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... ...................................................... 1.01 mm (.040 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3749 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ........................................................ 18 Nm (13 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3750 Spark Plug: Application and ID AC Type ............................................................................................................................................... ....................................................................... 41-928 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3751 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition Spark Plug: Service and Repair Conventional Ignition Description Description Removal Procedure 1. Turn the ignition key OFF. 2. Remove foreign material from around the spark plug holes. 3. Remove the wires from the plugs. 4. Remove the spark plug using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2 Install new plugs and tighten properly. 3. Reapply dielectric lubricant to the insulator boot. Tighten to 18 Nm (13 lb ft). 4. Reattach the boots to the plugs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Conventional Ignition > Page 3754 Spark Plug: Service and Repair Integrated Direct Ignition Removal Procedure Tools Required J 36011 Spark Plug Connector Assembly Removal Tool 1. Remove the negative battery cable. 2. Remove the integrated Direct Ignition (IDI) assembly 4 bolts and connector. 3. Remove by pulling straight up on the housing. 4. Use the J 36011 to remove connector assembly(s) is stuck to the spark plugs. Use the tools by first twisting then pulling up on the connector assembly. 5. Remove the debris from the area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start the spark plugs into the cylinder head and tighten. Tighten the plugs to 18 Nm (13 lb ft). 3. Reinstall onto the IDI any spark plug boot connector assembly that stuck to a spark plug. ^ Check to be sure the spring terminal is inside the boot. ^ Reapply dielectric lubricant to the insulator boot. 4. Locate the IDI assembly over the spark plugs and push straight down. 5. Remove any loose lubricant that is present on the IDI assembly to cam housing bolts. IMPORTANT: Hand start the IDI assembly to cam housing bolts. 6. Apply threadlocker onto the IDI assembly to cam housing bolts. Tighten the bolts to 22 Nm (16 lb ft). 7. Install the electrical connector. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3758 Compression Check: Testing and Inspection ENGINE COMPRESSION TEST Perform the following steps in order to conduct a compression test for VIN 4: 1. Conduct the following steps in order to check cylinder compression: 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module. 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). IMPORTANT: The results of a compression test will fall into the following categories: ^ Normal-Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings-Compression low on first stroke. Tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. ^ Valves-Compression low on first stroke. Does not tend to build up on the following strokes. Does not improve much with addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine uses hydraulic lifters and no valve lash adjustment is necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3782 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Intake Air Temperature (IAT) Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3802 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3803 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 3804 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3840 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the ECT sensor. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the IAT sensor through a resistor in the PCM and monitors the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3841 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the IAT sensor into the air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3845 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3846 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3847 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3883 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3884 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 3889 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3890 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3891 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3909 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3910 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3911 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3927 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3928 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3932 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3933 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3934 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3970 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3973 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Data Link Connector: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 Data Link Connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Data Link Connector: Electrical Diagrams Data Link Connector (DLC) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Data Link Connector (DLC) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 4012 Data Link Connector: Description and Operation There are two data lines that can be accessed with the scan tool. The Serial Data Line UART (800 Circuit) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing and Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 Circuit) allows the scan tool to directly access the Powertrain Control Module to read emissions related information. The scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4021 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4022 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4023 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4024 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4025 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4031 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4036 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4037 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4038 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4039 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4040 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4050 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4055 Powertrain Control Module: Specifications PCM Retainer Bolts 6-9 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4056 Powertrain Control Module: Locations Location View At the right front corner, behind the fascia Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Powertrain Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Powertrain Control Module: Connector Views Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 4094 Powertrain Control Module: Description and Operation Description The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control Control Module Function The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure Powertrain Control Module: Service and Repair Password Learn Procedure In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the PC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 4097 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) Replacement/Programming Repair Instructions NOTICE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. REMOVAL PROCEDURE IMPORTANT: Turn the ignition switch OFF to prevent internal PCM damage when disconnecting or reconnecting power to the PCM (for example, battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). The ignition switch should be OFF for at least 10 seconds before disconnecting the power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and the horn. NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 5. Disconnect the PCM electrical connectors (1). 6. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 4098 7. Slide the PCM and the retainer (1) from the PCM bracket (2). 8. Remove the retainer (1) from the PCM (2). INSTALLATION PROCEDURE Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the malfunctioning PCM. 1. Slide the PCM (2) into the PCM retainer (1). 2. Slide the PCM and the retainer (1) into the PCM bracket (2) slots. 3. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb ft). NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 4. Connect the PCM electrical connectors (1). 5. Install the horn and the horn attaching bolt. 6. Connect the horn electrical connector. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. 9. Reprogram the PCM and perform the Crankshaft Position System Variation Learning Procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4103 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4104 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4105 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4106 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4107 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4108 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4109 Fuel Level Sensor: Description and Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gauge. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4110 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Fuel level sensor (1) to the modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill the fuel tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition to the ON position for two seconds. 7.2. Turn the ignition to the OFF position for ten seconds. 7.3. Turn the ignition to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Valve: Specifications Attaching Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4117 Idle Air Control (IAC) Valve: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4118 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions Idle Air Control (IAC) Valve: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Idle Air Control (IAC) Valve: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Idle Air Control (IAC) Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4154 Idle Air Control (IAC) Valve: Description and Operation Engine idle speed is controlled by the PCM through the IAC valve (1) mounted on the throttle body. The PCM sends voltage pulses to the IAC valve motor windings causing the IAC valve pintle (3) to move IN (toward the seat) or OUT (away from the seat) a given distance (a step or count) for each pulse. The commanded location (steps away from the seated position) can be observed as a number of counts displayed on a scan tool. The pintle movement controls the airflow around the throttle valve (2), which in turn, controls engine idle speed: Pintle Extended=Decrease RPM=Lower Counts. Pintle Retracted=Increase RPM=Higher Counts. The controlled or desired idle speed for all engine operating conditions is programmed into the EEPROM of the PCM. The programmed engine speeds are based on coolant temperature, park/neutral switch status, vehicle speed, battery voltage, and A/C refrigerant pressure (if equipped). The PCM learns the proper IAC valve positions to achieve warm, stabilized idle speeds (RPM), desired for the various conditions (PIN or Drive, A/C ON or OFF, if equipped). This information is stored in PCM Keep Alive memories (information is retained after ignition is OFF). All other IAC valve positioning is calculated based on these memory values. As a result, engine variations due to wear, and variations in minimum throttle valve position (within limits) do not affect engine idle speeds. This system provides correct idle control under all conditions. This also means that disconnecting power to the PCM can result in incorrect idle control or the necessity to partially depress the accelerator when starting, until the PCM relearns idle control. ^ Engine idle speed is a function of total airflow into the engine based on IAC valve pintle position plus throttle valve opening plus calibrated vacuum loss through accessories. ^ The minimum throttle valve position is set at the factory with a stop screw. This setting allows enough air flow by the closed throttle valve to cause the IAC valve pintle to be positioned a calibrated number of steps (counts) from the seat during controlled idle operation. The minimum throttle valve position for this engine is not the same as the minimum idle speed associated with other fuel injected engines. The throttle stop screw is tilled at the factory following an adjustment. IMPORTANT: Do Not try to remove the filler and readjust the stop screw. Misadjustment may set a DTC P0506 or a DTC P0507. ^ The PCM normally resets the IAC valve pintle position once during each ignition cycle when vehicle speed increases above 20 mph on moderate acceleration. During the reset, the PCM commands the IAC valve pintle to retract completely, then move IN to the seated position (to establish the zero count position), and then back out to the desired position. The IAC is relearned only once per ignition cycle. ^ The IAC valve also can be reset without driving the vehicle by using this service procedure: 1. Turn ignition switch to the ON position (engine OFF). 2. Turn ignition OFF for ten seconds. 3. Start engine and check for proper idle operation. ^ Whenever the IAC valve is disconnected and reconnected while the engine is running, the resulting IAC valve counts may not correspond with the actual IAC valve pintle position. When servicing the IAC valve, it should only be disconnected or connected after the ignition has been OFF for at least 10 seconds. This allows time for the PCM to move the IAC valve to the 150 count position where it is parked while the ignition is OFF. Whenever this procedure is not followed, the PCM will lose track of IAC valve position resulting in starting or idle control problems until the IAC valve is reset and pintle position is relearned. ^ IAC system problems may cause improper idle speeds, resulting in a DTC P0506 or a DTC P0507. The DTC P0506 or the DTC P0507 tables should be used to diagnose these problems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4155 Idle Air Control (IAC) Valve: Testing and Inspection Refer to DTC P0506 or P0507 for diagnosis of the IAC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4156 Idle Air Control (IAC) Valve: Service and Repair REMOVAL PROCEDURE 1. Remove the IAC valve electrical connector. 2. Remove the IAC valve attaching screws (1). NOTICE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 3. Remove the IAC valve assembly (2). ^ Clean IAC valve O-ring sealing surface, pintle valve seat, and air passage. ^ The IAC valve may be cleaned, use a shop towel or parts cleaning brush to remove heavy deposits. ^ Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle shaft. ^ Whenever air passage have heavy deposits, remove throttle body for complete cleaning. ^ Inspect IAC valve O-ring for cuts, cracks, or distortion. Replace if damaged. ^ Whenever installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle shape and diameter are designed for the specific application. Measurement Procedure This procedure is only for installing a new IAC Valve. IMPORTANT: If installing a new IAC valve, replace the IAC valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. Measure the distance between tip of IAC valve pintle and mounting flange. If greater than 28 mm, use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. INSTALLATION PROCEDURE 1. Lubricate IAC valve O-ring (3) with clean engine oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4157 2. Install the IAC valve assembly (2). 3. Install the IAC valve attaching screws (1). Tighten the IAC valve attaching screws to 3.0 Nm (27 lb in). 4. Install the electrical connector. 5. To reset the IAC valve pintle position: 5.1. Turn the ignition switch to the ON position (engine OFF). 5.2. Turn the ignition switch OFF for ten seconds. 5.3. Start the engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation Information Bus: Description and Operation There are two data lines that can be accessed with the scan tool. The Serial Data Line UART (800 Circuit) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing and Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 Circuit) allows the scan tool to directly access the Powertrain Control Module to read emissions related information. The scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview 1. Check the scan tool operation on a known good vehicle to make sure tool is operating properly. 2. Check the condition of the CIG Fuse by visual inspection. 3. Verify that grounds G110 and G204 are clean and tight. 4. Check for proper connection of the scan tool to the Data Link Connector (DLC). 5. If all UART components are not accessible with a scan tool, check for an open, short to ground or short to B+ in the 800 circuit between the DLC terminal 9 and S277. 6. If a single UART component is not accessible with a scan tool, check for an open in the 800 circuit between the DLC and the suspect component. If OK, refer to Powertrain Control Module diagnosis, Antilock Brake System/Traction Control for ABS diagnosis, Supplement Inflatable Restraints for SIR diagnosis, and to Instrument Panel Cluster for Instrument Cluster diagnosis. See: Brakes and Traction Control See: Restraint Systems See: Instrument Panel, Gauges and Warning Indicators 7. If the Class 2 line to the PCM is not accessible with a scan tool, check for an open in the 1807 circuit between the PCM and the DLC. If OK, refer to Powertrain Control Module Diagnosis. ^ Check for a broken (or partially broken) wire inside the insulation which could cause system malfunction but prove good in a continuity/voltage check with a system disconnected. These circuits may be intermittent or resistive when loaded, and if possible, should be checked by monitoring for a voltage drop with the system operational (under load). ^ Check for proper installation of aftermarket electronic equipment which may affect the integrity of other systems. Refer to Troubleshooting Procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4163 Information Bus: Symptom Related Diagnostic Procedures Unable To Establish Serial Communication With Any Module (Part 1 Of 2) Unable To Establish Serial Communication With Any Module (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4164 Unable To Establish Serial Communication With EBCM Unable To Establish Serial Communication With SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4165 Scan Tool Cannot Communicate With The PCM On The UART Serial Data Bus (Part 1 Of 2) Scan Tool Cannot Communicate With The PCM On The UART Serial Data Bus (Part 2 Of 2) Scan Tool Cannot Communicate With The PCM On The Class 2 Serial Data Bus Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4166 Unable To Establish Serial Communication With Any Module (Part 1 Of 2) Unable To Establish Serial Communication With Any Module (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4167 Unable To Establish Serial Communication With EBCM Unable To Establish Serial Communication With SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4168 Information Bus: Component Tests and General Diagnostics There are two data lines that can be accessed with the scan tool. The Serial Data Line UART (800 Circuit) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing and Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 Circuit) allows the scan tool to directly access the Powertrain Control Module to read emissions related information. The scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4172 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4173 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4174 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4175 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4210 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4211 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor Module > Component Information > Description and Operation Knock Sensor Module: Description and Operation The KS module is an integral part of the PCM. The KS module is not serviceable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure (MAP) Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 4218 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4254 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gauge. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4255 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the throttle body. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold (2). INSTALLATION PROCEDURE 1. Install the MAP sensor (1) to the intake manifold (2). 2. Connect the MAP sensor electrical connector. 3. Install the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 4259 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 41 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor Oxygen Sensor: Locations Post Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4265 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4266 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4267 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4268 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4269 Oxygen Sensor: Locations Pre-Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4270 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4271 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Post Converter Heated Oxygen Sensor (HO2S 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 Oxygen Sensor: Description and Operation Oxygen Sensor 1 The Oxygen Sensor (O2S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). This voltage can be measured with a scan tool. By monitoring the voltage output of the O2S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low O2S 1 voltage = rich command - Rich mixture-high O2S 1 voltage = lean command The O2S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See the DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 > Page 4309 Oxygen Sensor: Description and Operation Rear Heated Oxygen Sensor The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 Oxygen Sensor: Service and Repair Oxygen Sensor 1 REMOVAL PROCEDURE NOTICE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail of connector could affect proper operation of the oxygen sensor. IMPORTANT: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the O2S 1. IMPORTANT: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). 1. Turn the ignition switch OFF 2. Disconnect the Oxygen Sensor 1 electrical connector. IMPORTANT: Do not use excessive force when removing the 02S sensor. 3. Carefully remove the Oxygen Sensor 1. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads to the oxygen sensor with anti-seize compound, if necessary. 2. Install the Oxygen Sensor 1. Tighten the 02S 1 41 Nm (30 lb ft). 3. Connect the Oxygen Sensor 1 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 > Page 4312 Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 REMOVAL PROCEDURE NOTICE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. IMPORTANT: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the 02S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. NOTICE: The use of excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb ft). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Powertrain Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4322 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4323 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4324 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4325 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4326 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4332 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM Powertrain Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM > Page 4337 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM > Page 4338 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM > Page 4339 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM > Page 4340 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99090 > May > 00 > Recall Corrosion/Moisture Entering the PCM > Page 4341 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Powertrain Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4351 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Powertrain Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4356 Powertrain Control Module: Specifications PCM Retainer Bolts 6-9 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4357 Powertrain Control Module: Locations Location View At the right front corner, behind the fascia Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Powertrain Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Powertrain Control Module: Connector Views Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 Connector View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 4395 Powertrain Control Module: Description and Operation Description The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control Control Module Function The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure Powertrain Control Module: Service and Repair Password Learn Procedure In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the PC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 4398 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) Replacement/Programming Repair Instructions NOTICE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. REMOVAL PROCEDURE IMPORTANT: Turn the ignition switch OFF to prevent internal PCM damage when disconnecting or reconnecting power to the PCM (for example, battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). The ignition switch should be OFF for at least 10 seconds before disconnecting the power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and the horn. NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 5. Disconnect the PCM electrical connectors (1). 6. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Password Learn Procedure > Page 4399 7. Slide the PCM and the retainer (1) from the PCM bracket (2). 8. Remove the retainer (1) from the PCM (2). INSTALLATION PROCEDURE Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the malfunctioning PCM. 1. Slide the PCM (2) into the PCM retainer (1). 2. Slide the PCM and the retainer (1) into the PCM bracket (2) slots. 3. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb ft). NOTICE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible Electrostatic Discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 4. Connect the PCM electrical connectors (1). 5. Install the horn and the horn attaching bolt. 6. Connect the horn electrical connector. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. 9. Reprogram the PCM and perform the Crankshaft Position System Variation Learning Procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Knock Sensor Module > Component Information > Description and Operation Knock Sensor Module: Description and Operation The KS module is an integral part of the PCM. The KS module is not serviceable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4442 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4443 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4444 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4480 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4481 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Instruments Erratic & Incorrect Engine Temp Reading File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-010 Date: March, 1999 TECHNICAL Subject: Erratic and Incorrect Engine Temperature Reading (Bleed Air from Cooling System) Models: 1998-99 Chevrolet Cavalier 1998-99 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some owners may comment about low coolant temperature gauge readings and when performing diagnosis, the technician may notice coolant temperature readings below the actual coolant temperature. Cause There may be a small pocket of air trapped in the coolant temperature sensor fitting on the radiator inlet pipe. This air pocket insulates the coolant temperature sensor from contact with the coolant flow causing low temperature gauge readings. Correction REMOVE THE TRAPPED AIR WITH THE FOLLOWING PROCEDURE: Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. 1. With the engine off and at ambient temperature, slowly remove the surge tank cap to relieve pressure from the cooling system. 2. Locate the Coolant Temperature Sensor on the Radiator Inlet Pipe. Notice: DO NOT APPLY TORQUE DIRECTLY TO THE RADIATOR INLET PIPE! Always use a back up wrench on the coolant temperature sensor fitting to prevent damage to the Radiator Inlet Pipe. 3. Observe the gap between the bottom of the hex on the coolant temperature sensor and the top of the hex on the fitting brazed to the radiator inlet pipe. It may be helpful at this point to mark the coolant temperature sensor thread with a reference mark 5 mm (0.196 in) down from the bottom of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Instruments - Erratic & Incorrect Engine Temp Reading > Page 4486 the hex on the sensor. 4. Slowly loosen the sensor (do not fully remove it) until coolant begins to weep out of the threads. This will allow any trapped air to escape and will ensure that the coolant is in contact with the sensor element. 5. Retighten the Coolant Temperature Sensor until there is a 5 mm (0.196 in) gap between the bottom of the hex on the sensor and the top of the hex on the coolant temperature sensor fitting. 6. Inspect the coolant level in the surge tank, if the coolant is low, add additional coolant to bring the level up to the "Full Cold" mark on the surge tank. Install the surge tank cap. 7. Start the vehicle and inspect the Coolant Temperature Sensor for leaks and correct temperature gauge readings. Warranty Information For vehicles repaired under warranty, use: Labor 0peration Labor Time J6368 0.3 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4487 Coolant Temperature Sensor/Switch (For Computer): Specifications Sensor 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4488 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 4524 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor (3) is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the resistance of the ECT sensor is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table may lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 4525 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL PROCEDURE NOTICE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. INSTALLATION PROCEDURE 1. Coat the threads (only) with sealer. 2. Install the ECT sensor. Tighten the ECT sensor to 25 Nm (18.5 lb. ft.). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4529 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4530 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4531 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4567 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4570 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4575 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4576 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4577 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4578 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4579 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4580 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4581 Fuel Level Sensor: Description and Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gauge. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4582 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Fuel level sensor (1) to the modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill the fuel tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition to the ON position for two seconds. 7.2. Turn the ignition to the OFF position for ten seconds. 7.3. Turn the ignition to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations Intake Air Temperature (IAT) Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 4590 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 4591 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Component Locations > Page 4592 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4628 Intake Air Temperature (IAT) Sensor: Description and Operation The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the ECT sensor. Low temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130°C/266°F). The PCM supplies a 5 volt signal to the IAT sensor through a resistor in the PCM and monitors the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 4629 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL PROCEDURE 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the IAT sensor into the air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4633 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4634 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4635 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4636 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4671 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4672 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure (MAP) Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 4676 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions Manifold Absolute Pressure (MAP) Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Manifold Absolute Pressure (MAP) Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4712 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gauge. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Diagrams > Page 4713 Manifold Absolute Pressure (MAP) Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the throttle body. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor (1) from the intake manifold (2). INSTALLATION PROCEDURE 1. Install the MAP sensor (1) to the intake manifold (2). 2. Connect the MAP sensor electrical connector. 3. Install the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations At the rear center of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 4717 Oil Pressure Sensor: Service and Repair Description REMOVAL PROCEDURE 1. Raise the vehicle. 2. Disconnect the electrical connector. 3. Remove the engine oil pressure sensor (1). INSTALLATION PROCEDURE 1. Install the engine oil pressure sensor (1). 2. Connect the electrical connector. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 41 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor Oxygen Sensor: Locations Post Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4723 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4724 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4725 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4726 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4727 Oxygen Sensor: Locations Pre-Converter Oxygen Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4728 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Post Converter Oxygen Sensor > Page 4729 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Post Converter Heated Oxygen Sensor (HO2S 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 Oxygen Sensor: Description and Operation Oxygen Sensor 1 The Oxygen Sensor (O2S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). This voltage can be measured with a scan tool. By monitoring the voltage output of the O2S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low O2S 1 voltage = rich command - Rich mixture-high O2S 1 voltage = lean command The O2S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See the DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor 1 > Page 4767 Oxygen Sensor: Description and Operation Rear Heated Oxygen Sensor The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 Oxygen Sensor: Service and Repair Oxygen Sensor 1 REMOVAL PROCEDURE NOTICE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail of connector could affect proper operation of the oxygen sensor. IMPORTANT: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the O2S 1. IMPORTANT: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). 1. Turn the ignition switch OFF 2. Disconnect the Oxygen Sensor 1 electrical connector. IMPORTANT: Do not use excessive force when removing the 02S sensor. 3. Carefully remove the Oxygen Sensor 1. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads to the oxygen sensor with anti-seize compound, if necessary. 2. Install the Oxygen Sensor 1. Tighten the 02S 1 41 Nm (30 lb ft). 3. Connect the Oxygen Sensor 1 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor 1 > Page 4770 Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 REMOVAL PROCEDURE NOTICE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. IMPORTANT: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the 02S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. NOTICE: The use of excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb ft). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4774 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4775 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4811 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4812 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4813 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4822 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4823 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 4829 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 4830 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4831 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4832 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 4835 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4836 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4837 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4842 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4843 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4844 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4845 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Vehicle Speed Sensor (VSS) (3T40) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4881 Vehicle Speed Sensor: Description and Operation The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Transmission for more information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4885 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4886 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4922 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4923 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4924 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4933 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4934 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4940 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 4941 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4942 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4943 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 4946 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4947 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4948 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4953 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4954 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4955 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 4956 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Vehicle Speed Sensor (VSS) (3T40) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4992 Vehicle Speed Sensor: Description and Operation The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Transmission for more information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Bracket Attaching Nut 70-106 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 5001 Canister Purge Control Valve: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 5002 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 5003 Evaporative Emission (EVAP) Canister Purge Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 5004 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams Evaporative Emission (EVAP) Canister Vent Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 5008 Canister Purge Solenoid: Service and Repair Description Description Description REMOVAL PROCEDURE 1. Remove the purge valve electrical connector. 2. Remove the hoses to the purge valve. 3. Remove the purge valve (1) from the mounting bracket (2). Description 4. When replacing the bracket, remove the purge valve mounting bracket attaching nut (1). 5. Remove the purge valve mounting bracket (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 5009 INSTALLATION PROCEDURE 1. Install the purge valve mounting bracket (2) and the attaching nut (1). Tighten the purge valve mounting bracket attaching nut to 8-12 Nm (70-106 lb in). 2. Slide the purge valve (1) into the mounting bracket (2). 3. Install the hoses to the purge valve. 4. Install the valve electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Description and Operation Canister Vent Valve: Description and Operation The Evaporative Canister Vent Valve replaces the fresh air vent used on the past EVAP canisters. The vent valve now not only allows the fresh outside air to the EVAP canister during the purge modes, but also allows the diagnostic to pull a vacuum on the fuel tank by closing the vent valve. This valve is normally open. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Description and Operation > Page 5014 Canister Vent Valve: Service and Repair Evap Canister And Vent Valve REMOVAL PROCEDURE 1. Remove the RH engine splash shield. 2. Disconnect the vent solenoid electrical connector. 3. Remove the vent solenoid hose clamp. 4. Disconnect the hose (3) to the vent solenoid (4). 5. Remove the vent solenoid (4) from mounting bracket. INSTALLATION PROCEDURE 1. Slide the vent solenoid onto the mounting bracket. 2. Lubricate the hose ends with lubricant. 3. Connect the hose (3) to the vent solenoid (4). 4. Connect the vent solenoid hose clamp. 5. Connect the vent solenoid electrical connector. 6. Install the RH engine splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair Evaporative Emissions Hose: Service and Repair REMOVAL PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: ^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. ^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. ^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one how; or more than 9O°C (194°F) for any extended period. ^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) NOTICE: Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter. 1. Remove the retaining hardware and clamps as necessary. 2. Note the location and position for future reference. 3. Inspect the hoses and vapor lines for cuts, swelling, cracks, kinks and distortion. 4. Remove the pipe or hose. INSTALLATION PROCEDURE IMPORTANT: Follow the same routing as the original pipe or hose. 1. Install the vapor line or hose. 2. Install the retaining hardware and clamps. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation Enhanced Evaporative Emission (EVAP) Service Port The Evaporative System Service Port is located in the evaporative hose located between the purge solenoid and the canister. The service port is identified by a green colored cap. The port contains a schrader valve and fittings in order to allow the connection of the service tool kit Enhanced EVAP Pressure Purge Diagnostic Cart J 41413. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications Flange Attaching Nut 19 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 5025 EGR Valve: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 5026 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 5027 Exhaust Gas Recirculation (EGR) Valve (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 5028 EGR Valve: Description and Operation Purpose An Exhaust Gas Recirculation (EGR) system is used to lower Oxides of Nitrogen (NOx) emission levels caused by high combustion temperatures. It accomplishes this by feeding small amounts of exhaust gases back into the combustion chamber. When the air/fuel mixture is diluted with the exhaust gases, combustion temperatures are reduced. Linear EGR Valve A linear EGR valve is used on this system. The linear EGR valve is designed to accurately supply exhaust gases to the engine without the use of intake manifold vacuum. The valve controls exhaust flow going into the intake manifold from the exhaust manifold through an orifice with a PCM controlled pintle. The PCM controls the pintle position using inputs from the Throttle Position (TP) and Manifold Absolute Pressure (MAP) sensors. The PCM then commands the EGR valve to operate when necessary by controlling a voltage signal through the PCM. This can be monitored on a scan tool as the desired EGR position. Linear EGR Control The PCM monitors the results of its command through a feedback signal. By sending a 5 volt reference and a ground to the EGR valve, a voltage signal representing the EGR valve pintle position is sent to the PCM. This feedback signal can also be monitored on a scan tool and is the actual position of the EGR pintle. The actual EGR position should always be near the commanded or the desired EGR position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 5029 EGR Valve: Service and Repair Description Description REMOVAL PROCEDURE 1. Remove the EGR electrical connector. 2. Remove the EGR valve flange nuts (1). 3. Remove the EGR valve (2) and the gasket (3). INSTALLATION PROCEDURE 1. With a new gasket (3), install the EGR valve (2). 2. Install the EGR valve and the flange attaching nuts (1). Tighten the EGR valve flange attaching nuts to 26 Nm (19 lb ft). 3. Install the electrical connectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fuel Filler Neck And Cap To help prevent refueling with leaded fuel, the fuel filler neck (1) has a built in restrictor and deflector. The opening in the restrictor will accept only the smaller unleaded gasoline fuel nozzle which must be fully inserted to bypass the deflector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure > Page 5038 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5039 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5040 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5041 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5042 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5043 Diagnostic Chart CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn OFF the in-tank fuel pump for 2 seconds after the ignition switch is turned ON or for 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. The unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION The number(s) below refer(s) to the step number(s) on the Diagnostic Table. 2. In order to relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gauge should be 284-325 kPa (41-47 psi). 3. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more of the following areas: ^ The fuel pump check valve ^ The fuel pump flex pipe ^ The valve or valve seat within the fuel pressure regulator ^ The fuel injector(s) 5. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or a misfire. You can use a scan tool in order to diagnose a lean condition. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. 8. When the engine is idling, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5044 the fuel pressure regulator. This will cause lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine turned OFF. 12. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition can cause a DTC P0132 or a DTC P0172 to set. Driveability conditions that are associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 13. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a malfunctioning fuel pressure regulator. 15. Fuel pressure being below 284 kPa (41 psi) can cause a lean condition. A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions that are associated with lean conditions can include hard starting (when the engine is cold), a hesitation, poor driveability, a lack of power, surging, and misfiring. 16. Restricting the fuel flow causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool in order to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gauge outlet hose is pinched. 22. Check the spark plug that is associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Control Pedal Accelerator Control Pedal Nuts 30 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 5054 Accelerator Pedal: Service and Repair REMOVAL PROCEDURE 1. Remove left sound insulator. 2. Remove the release cable (1) retainer from lever assembly. 3. Remove the nuts to cowl. 4. Remove the pedal assembly (2). INSTALLATION PROCEDURE 1. Install the pedal assembly (2) to cowl. 2. Install the nuts to cowl. Tighten the nuts to 30 Nm (25 lb ft). 3. Slip accelerator cable (1) through slot in rod and then install retainer in rod, being sure it is seated. 4. Install the left sound insulator. IMPORTANT: Flexible components (hoses, wires, conduits, etc.) must not be routed within 50 mm (2.0 in) of moving parts of accelerator linkage outboard of support unless routing is positively controlled. 5. Check for correct opening and closing positions by operating accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If it does not, inspect for damaged or bent brackets, levers, or other components; or, for poor carpet in under the accelerator pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5067 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5073 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5074 Air Filter Element: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. Refer to Maintenance. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. Tighten the upper air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fuel Filler Neck And Cap To help prevent refueling with leaded fuel, the fuel filler neck (1) has a built in restrictor and deflector. The opening in the restrictor will accept only the smaller unleaded gasoline fuel nozzle which must be fully inserted to bypass the deflector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5117 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5118 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5119 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5120 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5121 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5122 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5123 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5124 Fuel: Description and Operation The following information appears in the General Motors owner's manual for this vehicle. Use regular unleaded gasoline rated at 87 octane or higher. At a minimum, it should meet specifications ASTM D4814 in the United States and CGSB 3.5-M93 in Canada. Improved gasoline specifications have been developed by the American Automobile Manufacturers Association (AAMA) for better vehicle performance and engine protection. Gasolines meeting the AAMA specification could provide improved driveability and emission control system protection compared to other gasolines. Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. If it's bad enough, it can damage your engine. If you're using fuel rated at 87 octane or higher and you still hear heavy knocking, your engine needs service. But don't worry if you hear a little pinging noise when you're accelerating or driving up a hill. That's normal, and you don't have to buy a higher octane fuel to get rid of pinging. It's the heavy, constant knock that means you have a problem. If your vehicle is certified to meet California Emission Standards (indicated on the underhood tune-up label), it is designed to operate on fuels that meet California specifications. If such fuels are not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp on your instrument panel may turn on and/or your vehicle may fail a smog-check test. If this occurs, return to a qualified service outlet for diagnosis to determine the cause of failure. In the event it is determined that the cause of the condition is the type of fuels used, repairs may not be covered by your warranty. Some gasolines that are not reformulated for low emissions contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask your service station operator whether or not his fuel contains MMT. General Motors does not recommend the use of such gasolines. If fuels containing MMT are used, spark plug life may be reduced and your emission control system performance may be affected. The malfunction indicator lamp on your instrument panel may turn on. If this occurs, return to a qualified service outlet for service. To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent deposits from forming in your engine and fuel system, allowing your emission control system to function properly. Therefore, you should not have to add anything to the fuel. In addition, gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area to help clean the air. General Motors recommends that you use these gasolines if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Don't use it. It can corrode metal parts in your fuel system and also damage plastic and rubber parts. That damage wouldn't be covered under your warranty. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5125 Fuel: Testing and Inspection Draw the fuel sample from the bottom of the tank in order to detect any water present in the tank. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water (as indicated by a water layer at the bottom of the sample), Do Not use this procedure. Go to Fuel System Cleaning. 1. Fill a 100 ml cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water to bring the total fluid volume to 100 ml. Install a stopper on the cylinder. 3. Shake the cylinder vigorously for 10 to 15 seconds. 4. Carefully loosen the stopper to release the pressure. 5. Close the stopper and shake the cylinder vigorously again for 10 to 15 seconds. 6. Put the graduated cylinder on a level surface for approximately 5 minutes to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer (which would now contain both alcohol and water) will be greater than 10 ml. For example, if the volume of the lower layer increases to 15 ml, it indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat greater because this procedure does not extract all of the alcohol from the fuel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fuel Filler Neck And Cap NOTICE: If a fuel tank filler pipe cap requires replacement, use only a fuel tank filler pipe cap with the same features. Failure to use the correct fuel tank filler pipe cap can result in a sedous malfunction of the fuel system. The fuel tank filler neck (1) is equipped with a quarter-turn type fuel filler cap (2). A built in ratchet type torque limiting device prevents over tightening. In order to install, turn the fuel filler cap clockwise until a clicking noise is heard. This signals that the correct torque has been reached and the fuel filler cap is fully seated. A fuel filler cap that is not fully seated, may cause a malfunction in the emission system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Voltage Voltage ECT between 50-95 degrees F (10-35 degrees C) Injector Voltage Reading 4.7- 5.8 Volts Please refer to Fuel Injector Coil Test procedure at Computers and Contol Systems Testing. Resistance Ohms Resistance Ohms ECT between 50 - 95 degrees F (10 - 35 degrees C) Ohms 1.95-2.3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 5139 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop Fuel Injector Pressure Drop If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly. Pressure Drop 1.5 psi Fuel Injector Balance Test Example (Typical) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5140 Fuel Injector: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 5141 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 Fuel Injector: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Fuel Injector: Connector Views Fuel Injector #1 Fuel Injector #2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Fuel Injector #4 Fuel Injector #3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5177 Fuel Injector: Description and Operation The fuel injector assembly is a solenoid-operated device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the fuel injector solenoid (3), which opens a ball valve (1), allowing fuel to flow past the ball valve, and through a recessed flow director plate (2) at the injector outlet. The director plate has machined holes that control the fuel flow, generating a conical spray pattern of finely atomized fuel at the injector tip. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. A fuel injector that is stuck partly open would cause loss of pressure after the engine is shut down, so long crank times would be noticed on some engines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5178 Fuel Injector: Testing and Inspection Most GM manufacturers now use a voltage drop and/or a fuel pressure drop test to measure Fuel Injector Coil Integrity. These test sequences can be found in Computers and Control Systems, under A, C or System Diagnostic Charts. See: Computers and Control Systems/Testing and Inspection Within these tests you might find an "Ohm" reading of the Injector, but generally this measurement is No Longer Used to solely determine the Pass/Fail quality of the Injector coil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5179 Fuel Injector: Service and Repair REMOVAL PROCEDURE CAUTION: Relieve the fuel system pressure before servicing fuel system components In order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal Injury cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel In an approved container when the dIsconnection is complete. 1. Relieve fuel system pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner resonator. 4. Remove the fuel rail. 5. Remove the fuel injector retaining clip (2). 6. Remove the fuel injector (3). INSTALLATION PROCEDURE IMPORTANT: Each fuel injector is calibrated for a specific flow rate. When replacing fuel injectors, be sure to order the correct fuel injector for the application being serviced. IMPORTANT: When installing the fuel injector, care should be taken not to tear or mis-align the fuel injector O.rings. 1. Lubricate new fuel injector O-ring seals (1) (4) (5) with clean engine oil, and install on fuel injector assembly (3). 2. Install the fuel injector upper O-ring (1). 3. Install the fuel injector lower backup O-ring (4). 4. Install the fuel injector lower O-ring (5). 5. Install the fuel injector (3) to the fuel rail. 6. Install the fuel injector retaining clip (2). 7. Install the fuel rail. 8. Install the air cleaner resonator. 9. Connect the negative battery cable. 10. Inspect for leaks through the following steps: 10.1. Turn the ignition switch ON for two seconds. 10.2. Turn the ignition switch 0FF for ten seconds. 10.3. Turn the ignition switch ON. 10.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Bracket Attaching Screw 31 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5183 Fuel Pressure Regulator: Description and Operation The fuel pressure regulator assembly is a diaphragm-operated relief valve with fuel pump pressure on one side, and a regulator spring pressure and intake manifold vacuum on the other side. The regulator's function is to maintain a constant pressure differential across the injectors at all times. The pressure regulator compensates for engine load by increasing the fuel pressure as the engine vacuum drops. The fuel pressure regulator is serviced as a complete assembly. With the ignition ON and engine OFF (zero vacuum), fuel pressure should be 284-325 kPa (41-47 psi). Whenever the pressure is too low, poor performance and a DTC P0171 could result. Whenever the pressure is too high, excessive odor and a DTC P0172 could result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5184 Fuel Pressure Regulator: Service and Repair Description Description REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Remove the negative battery cable. 3. Remove the air cleaner outlet resonator. 4. Remove the fuel rail bracket (1). 5. Remove the pressure regulator bracket attaching screw (3). IMPORTANT: If the fuel pressure regulator is to be reinstalled, inspect filter screen for contamination. If contaminated, remove and discard. 6. Remove the pressure regulator assembly (2) and O-ring (4) (discard O-ring). INSTALLATION PROCEDURE 1. Lubricate new pressure regulator O-ring (4) with clean engine oil, then install on pressure regulator (2). 2. Install the pressure regulator bracket attaching screw (3) coated with appropriate thread-locking material. Tighten the pressure regulator bracket attaching screw to 3.5 Nm (31 lb in). 3. Install the fuel rail bracket (1). 3.1. Tighten the fuel rail bracket nut (4) to 10 Nm (89 lbs in). 3.2. Tighten the fuel rail bracket nut (3) to 25 Nm (18 lbs ft). 3.3. Tighten the fuel rail bracket bolt (2) to 25 Nm (18 lbs ft). 4. Install the air cleaner outlet resonator. 5. Connect the negative battery cable. 6. Inspect for leaks through the following steps: ^ Turn the ignition switch to the ON position for 2 seconds. ^ Turn the ignition switch to the OFF position for 10 seconds. ^ Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5185 ^ Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 5189 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 5190 Fuel Pressure Sensor/Switch: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the system fuel pressure. 3. Drain fuel tank. 4. Remove the fuel tank. 5. Remove the electrical connector from the fuel tank pressure sensor. 6. Remove the fuel tank pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure > Page 5196 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5197 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5198 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5199 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5200 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5201 Diagnostic Chart CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn OFF the in-tank fuel pump for 2 seconds after the ignition switch is turned ON or for 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. The unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION The number(s) below refer(s) to the step number(s) on the Diagnostic Table. 2. In order to relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gauge should be 284-325 kPa (41-47 psi). 3. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more of the following areas: ^ The fuel pump check valve ^ The fuel pump flex pipe ^ The valve or valve seat within the fuel pressure regulator ^ The fuel injector(s) 5. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or a misfire. You can use a scan tool in order to diagnose a lean condition. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. 8. When the engine is idling, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside of Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5202 the fuel pressure regulator. This will cause lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the engine turned OFF. 12. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition can cause a DTC P0132 or a DTC P0172 to set. Driveability conditions that are associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 13. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a malfunctioning fuel pressure regulator. 15. Fuel pressure being below 284 kPa (41 psi) can cause a lean condition. A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions that are associated with lean conditions can include hard starting (when the engine is cold), a hesitation, poor driveability, a lack of power, surging, and misfiring. 16. Restricting the fuel flow causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool in order to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gauge outlet hose is pinched. 22. Check the spark plug that is associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5238 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL PROCEDURE 1. Remove the relay center cover. 2. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation A woven plastic strainer is located on the lower end of the fuel sender. This filter prevents dirt from entering the fuel line and also stops water unless the filter becomes completely submerged in water. This filter is self cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, should this occur, the fuel tank should be removed and thoroughly cleaned and the tank filter replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 5242 Fuel Pump Pickup Filter: Service and Repair REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Drain the fuel tank. 3. Remove the fuel tank. 4. Remove the fuel sender assembly. 5. Note the strainer (1) position for future reference. 6. Support the reservoir with one hand and grasp the strainer with the other hand. 7. Use a screwdriver to pry the strainer ferrule off the reservoir. 8. Discard the strainer. INSTALLATION PROCEDURE 1. Install the new strainer (1) to reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Install the fuel sender assembly. 4. Install the fuel tank. 5. Refill tank. 6. Install the negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn the ignition switch to the ON position for two seconds. 7.2. Turn the ignition switch OFF position for ten seconds. 7.3. Turn the ignition switch to the ON position. 7.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Attaching Bolts 18 ft.lb Bracket Nut (Side) 89 in.lb Bracket Nut (Top) 18 ft.lb Bracket Bolt 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5246 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5247 Fuel Rail: Service and Repair Description REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Remove the negative battery cable. 3. Remove the air cleaner outlet resonator. 4. Remove the fuel rail bracket. 5. Remove the fuel injector electrical connectors by pushing in the wire connector clip and pulling the electrical connector away from the fuel injector. 6. Remove the fuel feed inlet pipe quick connect. 7. Remove the fuel return pipe quick connect. 8. Remove the fuel rail attaching bolts. 9. Remove the fuel rail assembly from the cylinder head. INSTALLATION PROCEDURE 1. Insert the fuel rail into the cylinder head. 2. Install the fuel rail attaching bolts. Tighten the fuel rail attaching bolts to 24 Nm (18 lbs ft). 3. Install the fuel feed inlet pipe quick connect. 4. Install the fuel return pipe quick connect. 5. Install the fuel injector electrical connectors. 6. Install the fuel rail bracket. 6.1. Tighten the fuel rail bracket nut (4) to 10 Nm (89 lbs in). 6.2. Tighten the fuel rail bracket nut (3) to 25 Nm (18 lbs ft). 6.3. Tighten the fuel rail bracket bolt (2) to 25 Nm (18 lbs ft). 7. Connect the negative battery cable. 8. Inspect for fuel leaks through the following steps: 8.1. Turn the ignition switch to the ON position for two seconds. 8.2. Turn the ignition switch to the OFF position for ten seconds. 8.3. Turn the ignition switch to the ON position. 8.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Specifications Fuel Return Line: Specifications Fuel Return Pipe Fuel Return Pipe Retainer Screw 53 in.lb Fuel Line Clamp Screw 89 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Chassis Hose/Pipes Fuel Return Line: Service and Repair Chassis Hose/Pipes REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. 3. Plug fuel lines. 4. Raise vehicle. 5. Remove the quick-connect fittings at fuel sender and nylon fuel feed and return connecting lines. 6. Plug the fuel pipes to prevent leakage. 7. Remove the fuel pipe mounting hardware from pipes. NOTICE: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 8. Remove the fuel pipes to be serviced. 9. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the line removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including hose overlap on fuel line. INSTALLATION PROCEDURE NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 1. Position the fuel pipe in the body clips. 2. Install the fuel pipe and hose hardware. 3. Remove the caps on the fuel pipes. 4. Install the quick-connect fittings on the fuel pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar). 5. Lower the vehicle. 6. Remove the caps covering the fuel lines if required. 7. Install the engine compartment fuel line quick-connect fittings. 8. Install the fuel filler cap. 9. Install the negative battery cable. 10. Inspect for fuel leaks through the following steps: 10.1. Turn the ignition switch to the ON position for two seconds. 10.2. Turn the ignition switch to the OFF position for ten seconds. 10.3. Turn the ignition switch to the ON position. 10.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Chassis Hose/Pipes > Page 5253 Fuel Return Line: Service and Repair Engine Hose/Pipes REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. 3. Plug the fuel lines. 4. Remove the engine fuel feed and return pipe retainer and screws. 5. Remove the fuel return pipe from the fuel pressure regulator using a back-up wrench. 6. Remove the fuel pipe from fuel rail. NOTICE: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 7. Discard O-rings. INSTALLATION PROCEDURE 1. Remove the plugs on the fuel pipes. 2. Install the new O-rings. 3. Install the fuel return pipe to the fuel pressure regulator. Tighten the retainer screw to the regulator to 6 Nm (53 lbs in). 4. Install the fuel feed pipe to the fuel rail using a back-up wrench. Tighten the fuel fitting to 30 Nm (22 lbs ft). 5. Install the quick-connect fittings. 6. Install the fuel line retainer. 7. Install the fuel line clamp screws. Tighten Fuel line clamp screws to 10 Nm (89 lbs in). 8. Install the negative battery cable. 9. Install the fuel filler cap. 10. Inspect for fuel leaks through the following steps: 10.1. Turn the ignition switch to the ON position for two seconds. 10.2. Turn the ignition switch to the OFF position for ten seconds. 10.3. Turn the ignition switch to the ON position. 10.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > NHTSA00V053000 > Feb > 00 > Recall 00V053000: CNG Fuel and/or Brake System Leak Fuel Supply Line: Recalls Recall 00V053000: CNG Fuel and/or Brake System Leak Vehicle Description: Passenger vehicles equipped with Bi-Fuel Compressed Natural Gas (CNG) vehicles. The CNG fuel line and the CNG high pressure regulator coolant lines can contact other fuel (gasoline) and brake lines on the vehicle. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. A brake fluid leak could disable a portion of the brake system, causing longer stopping distances. Gasoline leaking from a fuel pipe, in the presence of an ignition source, could cause a vehicle fire. Dealers will inspect and reposition the CNG fuel and coolant pipes and reposition/repair any damaged fuel or brake pipes as necessary. Owner notification began March 17, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > NHTSA00V053000 > Feb > 00 > Recall 00V053000: CNG Fuel and/or Brake System Leak Fuel Supply Line: All Technical Service Bulletins Recall 00V053000: CNG Fuel and/or Brake System Leak Vehicle Description: Passenger vehicles equipped with Bi-Fuel Compressed Natural Gas (CNG) vehicles. The CNG fuel line and the CNG high pressure regulator coolant lines can contact other fuel (gasoline) and brake lines on the vehicle. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. A brake fluid leak could disable a portion of the brake system, causing longer stopping distances. Gasoline leaking from a fuel pipe, in the presence of an ignition source, could cause a vehicle fire. Dealers will inspect and reposition the CNG fuel and coolant pipes and reposition/repair any damaged fuel or brake pipes as necessary. Owner notification began March 17, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Page 5267 Fuel Supply Line: Specifications Fuel Feed Line Fuel Feed Line Fitting 22 ft.lb Fuel Line Clamp Screw 89 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Chassis Hose/Pipes Fuel Supply Line: Service and Repair Chassis Hose/Pipes REMOVAL PROCEDURE 1. Relieve fuel system pressure. 2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. 3. Plug fuel lines. 4. Raise vehicle. 5. Remove the quick-connect fittings at fuel sender and nylon fuel feed and return connecting lines. 6. Plug the fuel pipes to prevent leakage. 7. Remove the fuel pipe mounting hardware from pipes. NOTICE: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 8. Remove the fuel pipes to be serviced. 9. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the line removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including hose overlap on fuel line. INSTALLATION PROCEDURE NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 1. Position the fuel pipe in the body clips. 2. Install the fuel pipe and hose hardware. 3. Remove the caps on the fuel pipes. 4. Install the quick-connect fittings on the fuel pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar). 5. Lower the vehicle. 6. Remove the caps covering the fuel lines if required. 7. Install the engine compartment fuel line quick-connect fittings. 8. Install the fuel filler cap. 9. Install the negative battery cable. 10. Inspect for fuel leaks through the following steps: 10.1. Turn the ignition switch to the ON position for two seconds. 10.2. Turn the ignition switch to the OFF position for ten seconds. 10.3. Turn the ignition switch to the ON position. 10.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Chassis Hose/Pipes > Page 5270 Fuel Supply Line: Service and Repair Engine Hose/Pipes REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. 3. Plug the fuel lines. 4. Remove the engine fuel feed and return pipe retainer and screws. 5. Remove the fuel return pipe from the fuel pressure regulator using a back-up wrench. 6. Remove the fuel pipe from fuel rail. NOTICE: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 7. Discard O-rings. INSTALLATION PROCEDURE 1. Remove the plugs on the fuel pipes. 2. Install the new O-rings. 3. Install the fuel return pipe to the fuel pressure regulator. Tighten the retainer screw to the regulator to 6 Nm (53 lbs in). 4. Install the fuel feed pipe to the fuel rail using a back-up wrench. Tighten the fuel fitting to 30 Nm (22 lbs ft). 5. Install the quick-connect fittings. 6. Install the fuel line retainer. 7. Install the fuel line clamp screws. Tighten Fuel line clamp screws to 10 Nm (89 lbs in). 8. Install the negative battery cable. 9. Install the fuel filler cap. 10. Inspect for fuel leaks through the following steps: 10.1. Turn the ignition switch to the ON position for two seconds. 10.2. Turn the ignition switch to the OFF position for ten seconds. 10.3. Turn the ignition switch to the ON position. 10.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5276 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5277 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5278 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5279 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5280 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5281 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Tank HARN CONN to Fuel Pressure SEN/Fuel Tank MOD Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Tank HARN CONN to Fuel Pressure SEN/Fuel Tank MOD > Page 5286 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 5287 Fuel Tank Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 5288 Fuel Tank Unit: Description and Operation Modular Fuel Sender The modular fuel sender assembly mounts in the top of the fuel tank and is spring loaded to the bottom. It is designed to: ^ Provide optimum fuel level in the internal fuel reservoir during all fuel tank levels and driving conditions. ^ Improve the measuring accuracy of fuel tank level. ^ Filters coarse contaminates from the fuel. ^ House fuel pump and helps prevent fuel pump noise. ^ Include a check valve to inhibit back flow of fuel from fuel system. The fuel sender consists of the following serviceable components: ^ Fuel strainer. ^ Fuel level sensor. ^ Fuel tank pressure sensor. ^ Fuel sender O-ring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 5289 Fuel Tank Unit: Service and Repair REMOVAL PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the negative battery cable. 2. Relieve the fuel system pressure. 3. Drain the fuel tank. 4. Remove the fuel tank (4). IMPORTANT: ^ The modular fuel sender assembly may spring up from its position. ^ When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one. ^ Carefully discard the reservoir fuel into an approved container. 5. While holding the modular fuel sender assembly (3) down, remove the snap ring (1) from designated slots located on the retainer (2). 6. Remove the fuel sender assembly from the fuel tank. INSTALLATION PROCEDURE 1. Install a new O-ring on modular fuel sender (3) to tank. 2. Align tab on front of sender (2) with slot on front of retainer snap ring. 3. Slowly apply pressure to top of spring loaded sender until sender aligns flush with retainer on tank. IMPORTANT: Be sure that the snap ring is fully seated within the tab slots. 4. Insert snap ring (1) into designated slots. 5. Install the fuel tank. 6. Lower vehicle. 7. Refill tank. 8. Connect the negative battery cable. 9. Inspect for fuel leaks through the following steps: 9.1. Turn the ignition to the ON position for two seconds 9.2. Turn the ignition to the OFF position for ten seconds. 9.3. Turn the ignition to the ON position 9.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Valve: Specifications Attaching Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5293 Idle Air Control (IAC) Valve: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5294 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions Idle Air Control (IAC) Valve: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Idle Air Control (IAC) Valve: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Idle Air Control (IAC) Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5330 Idle Air Control (IAC) Valve: Description and Operation Engine idle speed is controlled by the PCM through the IAC valve (1) mounted on the throttle body. The PCM sends voltage pulses to the IAC valve motor windings causing the IAC valve pintle (3) to move IN (toward the seat) or OUT (away from the seat) a given distance (a step or count) for each pulse. The commanded location (steps away from the seated position) can be observed as a number of counts displayed on a scan tool. The pintle movement controls the airflow around the throttle valve (2), which in turn, controls engine idle speed: Pintle Extended=Decrease RPM=Lower Counts. Pintle Retracted=Increase RPM=Higher Counts. The controlled or desired idle speed for all engine operating conditions is programmed into the EEPROM of the PCM. The programmed engine speeds are based on coolant temperature, park/neutral switch status, vehicle speed, battery voltage, and A/C refrigerant pressure (if equipped). The PCM learns the proper IAC valve positions to achieve warm, stabilized idle speeds (RPM), desired for the various conditions (PIN or Drive, A/C ON or OFF, if equipped). This information is stored in PCM Keep Alive memories (information is retained after ignition is OFF). All other IAC valve positioning is calculated based on these memory values. As a result, engine variations due to wear, and variations in minimum throttle valve position (within limits) do not affect engine idle speeds. This system provides correct idle control under all conditions. This also means that disconnecting power to the PCM can result in incorrect idle control or the necessity to partially depress the accelerator when starting, until the PCM relearns idle control. ^ Engine idle speed is a function of total airflow into the engine based on IAC valve pintle position plus throttle valve opening plus calibrated vacuum loss through accessories. ^ The minimum throttle valve position is set at the factory with a stop screw. This setting allows enough air flow by the closed throttle valve to cause the IAC valve pintle to be positioned a calibrated number of steps (counts) from the seat during controlled idle operation. The minimum throttle valve position for this engine is not the same as the minimum idle speed associated with other fuel injected engines. The throttle stop screw is tilled at the factory following an adjustment. IMPORTANT: Do Not try to remove the filler and readjust the stop screw. Misadjustment may set a DTC P0506 or a DTC P0507. ^ The PCM normally resets the IAC valve pintle position once during each ignition cycle when vehicle speed increases above 20 mph on moderate acceleration. During the reset, the PCM commands the IAC valve pintle to retract completely, then move IN to the seated position (to establish the zero count position), and then back out to the desired position. The IAC is relearned only once per ignition cycle. ^ The IAC valve also can be reset without driving the vehicle by using this service procedure: 1. Turn ignition switch to the ON position (engine OFF). 2. Turn ignition OFF for ten seconds. 3. Start engine and check for proper idle operation. ^ Whenever the IAC valve is disconnected and reconnected while the engine is running, the resulting IAC valve counts may not correspond with the actual IAC valve pintle position. When servicing the IAC valve, it should only be disconnected or connected after the ignition has been OFF for at least 10 seconds. This allows time for the PCM to move the IAC valve to the 150 count position where it is parked while the ignition is OFF. Whenever this procedure is not followed, the PCM will lose track of IAC valve position resulting in starting or idle control problems until the IAC valve is reset and pintle position is relearned. ^ IAC system problems may cause improper idle speeds, resulting in a DTC P0506 or a DTC P0507. The DTC P0506 or the DTC P0507 tables should be used to diagnose these problems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5331 Idle Air Control (IAC) Valve: Testing and Inspection Refer to DTC P0506 or P0507 for diagnosis of the IAC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5332 Idle Air Control (IAC) Valve: Service and Repair REMOVAL PROCEDURE 1. Remove the IAC valve electrical connector. 2. Remove the IAC valve attaching screws (1). NOTICE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 3. Remove the IAC valve assembly (2). ^ Clean IAC valve O-ring sealing surface, pintle valve seat, and air passage. ^ The IAC valve may be cleaned, use a shop towel or parts cleaning brush to remove heavy deposits. ^ Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle shaft. ^ Whenever air passage have heavy deposits, remove throttle body for complete cleaning. ^ Inspect IAC valve O-ring for cuts, cracks, or distortion. Replace if damaged. ^ Whenever installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle shape and diameter are designed for the specific application. Measurement Procedure This procedure is only for installing a new IAC Valve. IMPORTANT: If installing a new IAC valve, replace the IAC valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. Measure the distance between tip of IAC valve pintle and mounting flange. If greater than 28 mm, use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. INSTALLATION PROCEDURE 1. Lubricate IAC valve O-ring (3) with clean engine oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 5333 2. Install the IAC valve assembly (2). 3. Install the IAC valve attaching screws (1). Tighten the IAC valve attaching screws to 3.0 Nm (27 lb in). 4. Install the electrical connector. 5. To reset the IAC valve pintle position: 5.1. Turn the ignition switch to the ON position (engine OFF). 5.2. Turn the ignition switch OFF for ten seconds. 5.3. Start the engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair Fresh Air Intake REMOVAL PROCEDURE 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner intake duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner intake duct lower retaining screw. 11. Remove the front air cleaner intake duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. INSTALLATION PROCEDURE 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb in). 3. Install the front air cleaner intake duct through the headlamp assembly opening. 4. Install the front air cleaner intake duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner intake duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb in). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5373 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL PROCEDURE 1. Remove the relay center cover. 2. Remove the fuel pump relay. INSTALLATION PROCEDURE 1. Install the fuel pump relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Specifications Resonator: Specifications Intake Air Resonator Intake Air Resonator Resonator Bolt 61 in.lb Outlet Clamp 44 in.lb Outlet Mounting Screw 53 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Specifications > Page 5377 Resonator: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator mounting screw (4). 2. Disconnect the air cleaner outlet resonator clamp at the throttle body (2). 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose clamp (3) and the crankcase vent hose from the top of the engine. 5. Remove the air cleaner outlet resonator (1). INSTALLATION PROCEDURE 1. Connect the crankcase vent hose and crankcase vent hose clamp (3) to the top of the engine. IMPORTANT: Be sure that the air cleaner outlet resonator seals to the throttle body. 2. Install the air cleaner outlet resonator (1) to the throttle body (2). 3. Install the air cleaner outlet resonator mounting screw (4). ^ Tighten the air cleaner outlet resonator mounting screw to 10 Nm (89 lb in). ^ Tighten the air cleaner outlet resonator clamp to 5 Nm (44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten the air cleaner outlet duct clamps to 5 Nm (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 5417 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 5418 Fuel Pressure Sensor/Switch: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Relieve the system fuel pressure. 3. Drain fuel tank. 4. Remove the fuel tank. 5. Remove the electrical connector from the fuel tank pressure sensor. 6. Remove the fuel tank pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5422 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5423 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5459 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5460 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5461 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Attaching Bolts 10 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 5465 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 5466 Throttle Body: Service and Repair Description REMOVAL PROCEDURE 1. Remove the negative battery cable. 2. Remove the air cleaner resonator from the throttle body. 3. Remove the electrical connectors from the IAC valve and the TP sensors. 4. Remove the vacuum hoses at the throttle body. 5. Remove the throttle, cruise, and transmission control cables. 6. Remove the accelerator cable bracket. 7. Remove the throttle body attaching bolts (2). 8. Loosen the throttle body (1) from the intake manifold. INSTALLATION PROCEDURE NOTICE: The EVAP canister may have released carbon particles which caused this part to fail. Check the EVAP canister for loose carbon before returning the vehicle to service. 1. Install the throttle body (1). 2. Install the accelerator cable bracket. 3. Install the throttle body attaching bolts (2). Tighten the throttle body attaching bolts to 10 Nm (89 lb in). 4. Install the throttle, cruise, and transmission control cables to the throttle body. 5. Install the vacuum hoses to the throttle body. 6. Install the electrical connectors to the IAC valve and TP sensors. 7. Install the air cleaner resonator to the throttle body. IMPORTANT: With the engine OFF, check to see that the accelerator pedal is free, by depressing the pedal to the floor and releasing. 8. Install the negative battery cable. 9. Reset IAC valve pintle position: 9.1. Turn the ignition switch to the ON position. 9.2. Turn the ignition switch to the OFF position for ten seconds. 9.3. Start the engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Control Cable Accelerator Control Cable Cable Retaining Clip 10 Nm Cable Bracket 25 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable Throttle Cable/Linkage: Service and Repair Accelerator Cable REMOVAL PROCEDURE 1. Remove left sound insulator. 2. Remove release cable retainer from pedal assembly (2). 3. Depress the cable tangs (1) and push forward toward engine compartment. 4. Remove the cable retaining clip (2). 5. Remove the cable from the push-clip (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 5472 Description 6. Remove the cruise control cable if equipped. 7. Depress the tangs (1) on the cable and push through the cable bracket (2). 8. Remove the cable (3) from the cam. INSTALLATION PROCEDURE 1. Route cable through cable bracket (2). 2. Press cable upward through bracket. 3. Ensure tangs (1) expand and are properly seated. 4. Install the cruise control cable. 5. Install the cable in the push-in clip (1). 6. Install the cable retaining clip (2). Tighten cable retaining clip to 10 Nm (89 lb in). 7. Route the cable (3) through cowl. 8. Slip accelerator cable (2) through slot in rod and then install retainer in rod, being sure it is seated. IMPORTANT: Flexible components (hoses, wires, conduits, etc.) must not be routed within 50 mm (2.0 in) of moving parts of accelerator linkage outboard of support unless routing is positively controlled. 9. Check for correct opening and closing positions by operating accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If it does not, inspect for damaged or bent brackets, levers, or other components; or, for poor carpet fit under the accelerator pedal. 10. Install the left sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Cable > Page 5473 Throttle Cable/Linkage: Service and Repair Accelerator Cable Bracket Description REMOVAL PROCEDURE 1. Remove the accelerator, cruise and transmission cables, (If so equipped). 2. Remove the accelerator cable bracket attaching bolts (1) and the accelerator cable bracket (2). INSTALLATION PROCEDURE 1. Install the accelerator cable bracket (2) with attaching bolts (1). NOTICE: Align the accelerator bracket with the accelerator cam in order to prevent cable wear which could cause the cable to break. Tighten bolts to 25 Nm (18 lb ft). 2. Install the accelerator cable, cruise and transmission cables, (If so equipped). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TP Screws 3 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5477 Throttle Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5478 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5514 Throttle Position Sensor: Description and Operation TP Sensor Service The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor Replacement for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5515 Throttle Position Sensor: Testing and Inspection When the PCM detects a malfunction with the Throttle Position (TP) sensor circuits, the following Diagnostic Trouble Code (DTC)s will set: ^ DTC P0121 circuit performance. ^ DTC P0122 circuit low. ^ DTC P0123 circuit high. Refer to System Diagnosis / Diagnostic Tables for testing information. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5516 Throttle Position Sensor: Service and Repair TP Sensor Service REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1). 4. Remove the TP sensor (2). INSTALLATION PROCEDURE 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. IMPORTANT: Install the new TP sensor attaching screws when replacing the TP sensor. 2. Install the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb in). 3. Install the throttle body. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5533 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5534 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5535 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5571 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5572 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5576 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5577 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5578 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5614 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5617 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation Ignition Coil: Description and Operation Two separate coils are mounted inside the housing. Each coil provides the spark for two plugs simultaneously (waste spark distribution). Each coil can also be replaced separately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Cover Bolts 16 ft.lb Screws 35 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications > Page 5627 Ignition Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications > Page 5628 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications > Page 5629 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > C1 Ignition Control Module (C1) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > C1 > Page 5632 Ignition Control Module (C2) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 5633 Ignition Control Module: Description and Operation This system uses the same circuits between the ICM and the PCM that distributor type systems use. Following is a brief description for each of the IC circuits. Crankshaft Position (CKP) Sensor Activity (7X reference) - The CKP sensor generates a signal to the ICM which results in a reference pulse (square wave signal) being sent to the PCM. The PCM uses this signal to calculate crankshaft position, engine speed and injector pulse width. The engine will not start or run if this circuit is open or grounded. Reference Low - This wire is grounded through the ICM and insures that the ground circuit has no voltage drop between the ICM and the PCM which could affect performance. The PCM compares voltage pulses on the 7X or reference input to those on this circuit, ignoring any pulses that appear on both. A pulse that appears on the reference low circuit alone is assumed to be caused by Radio Frequency Interference (RFI). Ignition Control (IC) 1 & 2 - The PCM sends the ignition control pulse to the ICM on these circuits. These signals are similar to the 7X reference pulse square wave except that the PCM uses sensor inputs to determine the pulse timing to control spark advance. When the PCM receives the 7X signal, it will determine which pair of cylinders will be fired (1 & 4 or 2 & 3). It then tells the ICM which cylinder to fire through the ignition control circuits. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Page 5634 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the ignition coils from the module (1). 4. Remove the module from the assembly plate. INSTALLATION PROCEDURE 1. Install the module to the assembly plate 2. Install the ignition coils. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5638 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5639 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5640 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5641 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5676 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5677 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications Ignition Control Module: Specifications Cover Bolts 16 ft.lb Screws 35 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 5682 Ignition Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 5683 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Page 5684 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 Ignition Control Module (C1) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > C1 > Page 5687 Ignition Control Module (C2) (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 5688 Ignition Control Module: Description and Operation This system uses the same circuits between the ICM and the PCM that distributor type systems use. Following is a brief description for each of the IC circuits. Crankshaft Position (CKP) Sensor Activity (7X reference) - The CKP sensor generates a signal to the ICM which results in a reference pulse (square wave signal) being sent to the PCM. The PCM uses this signal to calculate crankshaft position, engine speed and injector pulse width. The engine will not start or run if this circuit is open or grounded. Reference Low - This wire is grounded through the ICM and insures that the ground circuit has no voltage drop between the ICM and the PCM which could affect performance. The PCM compares voltage pulses on the 7X or reference input to those on this circuit, ignoring any pulses that appear on both. A pulse that appears on the reference low circuit alone is assumed to be caused by Radio Frequency Interference (RFI). Ignition Control (IC) 1 & 2 - The PCM sends the ignition control pulse to the ICM on these circuits. These signals are similar to the 7X reference pulse square wave except that the PCM uses sensor inputs to determine the pulse timing to control spark advance. When the PCM receives the 7X signal, it will determine which pair of cylinders will be fired (1 & 4 or 2 & 3). It then tells the ICM which cylinder to fire through the ignition control circuits. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Page 5689 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the ignition coils from the module (1). 4. Remove the module from the assembly plate. INSTALLATION PROCEDURE 1. Install the module to the assembly plate 2. Install the ignition coils. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Sensor 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5694 Camshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5695 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5696 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Camshaft Position (CMP) Sensor (LN2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5732 Camshaft Position Sensor: Description and Operation IMPORTANT: Preform a Crankshaft Position System Variation Learning Procedure any time you make a change to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect a misfire at all speeds and loads accurately. Resulting in possibly setting a false misfire DTC. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could set if you do not perform this procedure. Refer to Crankshaft Position System Variation Learning Procedure. The Camshaft Position Sensor (CMP) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the EI system. A malfunction in the CMP sensor circuits will cause a DTC P0341 or P0342 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5733 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the R.H. tire assembly. 3. Remove the Camshaft Position (CMP) sensor electrical connector. 4. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the Camshaft Position (CMP) sensor. 2. Install the CMP sensor electrical connector. 3. Install the R.H. tire assembly. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Sensor Bolt 88 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5737 Crankshaft Position Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5738 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5739 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5775 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor provides a signal to the electronic Ignition Control Module (ICM), which the PCM uses as a reference to calculate RPM and crankshaft position. A fault in the CKP sensor circuits will cause a DTC P0335. This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the block within approximately 0.050 of the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined into it, six of which are equally spaced (60 degrees apart). A seventh slot, is spaced 10 degrees from one of the other slots and serves to generate a sync-pulse. As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the CKP sensor pulses, the ICM sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The ICM continues to send these reference pulse to the PCM at a rate of seven per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. The 7X reference signal is necessary for the PCM to determine when to activate the fuel injectors. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the sync pulse signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crankshaft sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. Refer to the CKP System Variation Learn Procedure for the Crankshaft Position System Variation Learning Procedure. See Electronic Ignition System Diagnosis for further information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Description REMOVAL PROCEDURE 1. Raise the vehicle. Suitably support the vehicle. 2. Remove the Crankshaft Position (CKP) sensor harness connector at the module. 3. Remove the CKP sensor mounting bolt (2). 4. Remove the CKP sensor from the engine (1). 5. Inspect the CKP sensor O-ring for wear, cracks or leakage. Replace if necessary. INSTALLATION PROCEDURE 1. Install the Crankshaft Position (CKP) sensor (1) into the block. 2. Install the CKP sensor mounting bolt (2). Tighten the CKP sensor mounting bolts to 8 Nm (71 lb in). 3. Install the CKP sensor harness connector. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5778 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Procedure IMPORTANT: A Crankshaft Position System Variation Learning Procedure must be performed any time a change is made to the crankshaft sensor to crankshaft relationship. Changing the crank sensor to crankshaft relationship will not allow the PCM to detect misfire at all speeds and loads accurately. Resulting in a possible false misfire DTC being set. Removing a part for inspection and then reinstalling the same part is considered a disturbance. A false DTC P0300 could be set if this procedure is not performed. The learn procedure is required after the following service procedures have been performed, regardless of whether or not DTC P1336 is set: ^ PCM replacement. ^ Engine replacement. ^ Crankshaft replacement. ^ Crankshaft position sensor replacement. ^ Any engine repair(s) which disturbs the crankshaft/harmonic balancer to the crankshaft position sensor relationship. CAUTION: When performing the Crankshaft Position System Variation Learning Procedure always set the vehicle parking brake and block the drive wheels in order to prevent Personal injury. Release the throttle immediately when the engine starts to decelerate. Once the learn procedure is completed, engine control will be returned to the operator and the engine will respond to throttle position. IMPORTANT: The battery must be fully charged and in good condition. The scan tool connection at the DLC is clean and tight before starting the Crankshaft Position System Variation Learning Procedure. 1. Close the hood. 2. Block the drive wheels and set the vehicle parking brake. 3. Put the vehicle in Park or Neutral. 4. Turn all the accessories OFF. 5. Install a scan tool. 6. Start and run the engine until it is at normal operating temperature 85°C (185°F). 7. With the engine still running, enable the Crankshaft Position System Variation Learning Procedure with the scan tool. 8. Press and hold the brake pedal firmly and raise the engine speed to the specified value, RELEASING the throttle as soon as the engine cuts out. 9. Verify with the scan tool that the crankshaft variation has been learned. Perform this procedure up to 10 times. If the PCM will not learn the variation, a DTC P1336 should be set. Refer to DTC P1336 CKP System Variation Not Learned for diagnosis. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor 12-16 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5787 Knock Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5788 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5789 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5790 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5825 Knock Sensor: Description and Operation Knock Sensor Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The KS system has two major components: ^ The KS module. ^ The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable. The KS detects abnormal vibration (spark knocking) in the engine. The sensor is mounted in the engine block near the cylinders. The sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is sent to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce the spark knock. A malfunction in the KS circuit or module will set a DTC P0325. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5826 Knock Sensor: Service and Repair Knock Sensor Wiring Harness Connector Knock Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise the vehicle. Suitably support the vehicle. 3. Remove the Knock Sensor wiring harness connector from the knock sensor. 4. Remove the knock sensor from the engine block. INSTALLATION PROCEDURE 1. After cleaning the threads thoroughly, install the knock sensor into the engine block. Tighten the knock sensor to 16-22 Nm (12-16 lb ft). 2. Install the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... ...................................................... 1.01 mm (.040 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 5831 Spark Plug: Specifications Spark Plug Torque Spark Plug Torque ............................................................................................................................... ........................................................ 18 Nm (13 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5832 Spark Plug: Application and ID AC Type ............................................................................................................................................... ....................................................................... 41-928 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5833 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Conventional Ignition Spark Plug: Service and Repair Conventional Ignition Description Description Removal Procedure 1. Turn the ignition key OFF. 2. Remove foreign material from around the spark plug holes. 3. Remove the wires from the plugs. 4. Remove the spark plug using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2 Install new plugs and tighten properly. 3. Reapply dielectric lubricant to the insulator boot. Tighten to 18 Nm (13 lb ft). 4. Reattach the boots to the plugs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Conventional Ignition > Page 5836 Spark Plug: Service and Repair Integrated Direct Ignition Removal Procedure Tools Required J 36011 Spark Plug Connector Assembly Removal Tool 1. Remove the negative battery cable. 2. Remove the integrated Direct Ignition (IDI) assembly 4 bolts and connector. 3. Remove by pulling straight up on the housing. 4. Use the J 36011 to remove connector assembly(s) is stuck to the spark plugs. Use the tools by first twisting then pulling up on the connector assembly. 5. Remove the debris from the area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. Installation Procedure 1. Adjust the spark plug gap using a round wire type spark plug gap gauge. While gapping the plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start the spark plugs into the cylinder head and tighten. Tighten the plugs to 18 Nm (13 lb ft). 3. Reinstall onto the IDI any spark plug boot connector assembly that stuck to a spark plug. ^ Check to be sure the spring terminal is inside the boot. ^ Reapply dielectric lubricant to the insulator boot. 4. Locate the IDI assembly over the spark plugs and push straight down. 5. Remove any loose lubricant that is present on the IDI assembly to cam housing bolts. IMPORTANT: Hand start the IDI assembly to cam housing bolts. 6. Apply threadlocker onto the IDI assembly to cam housing bolts. Tighten the bolts to 22 Nm (16 lb ft). 7. Install the electrical connector. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5848 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5849 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5855 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5856 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 5857 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5861 Brake Transaxle Shift Interlock (BTSI) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 5866 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Valve To Valve Body ......................................................................................................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle > Page 5872 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5873 Torque Converter Clutch Solenoid: Service and Repair REMOVAL PROCEDURE 1. Remove the valve body cover. Refer to Valve Body Cover Replacement. 2. Remove the transmission mount bracket. 3. Disconnect the solenoid wire harness from the case electrical connector. 4. Disconnect the wire leads from the pressure switch. 5. Remove the torque converter clutch solenoid bolt from the control valve body. 6. Remove the 3rd clutch pressure switch. 7. Remove the 2nd clutch pressure switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5874 1. Install the 2nd clutch pressure switch, if applicable. ^ Tighten to 12 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install 3rd clutch pressure switch. ^ Tighten to 12 Nm (124 inch lbs.). 3. Install the torque converter clutch solenoid bolt to the control valve body. 4. Install the 0-ring. ^ Tighten to 12 Nm (124 inch lbs.). 5. Connect the wire leads to the pressure switch. 6. Connect the solenoid wire harness to the case electrical connector. 7. Install the transmission mount bracket. 8. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 9. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 5881 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 5882 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5891 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5892 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5898 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5899 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5900 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5901 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 5904 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5905 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5906 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5910 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 5913 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 5914 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 5915 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON PROM - Programmable Read Only Memory: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5924 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5925 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 87-65-19 > May > 98 > PCM - DTC U1016 Stored With No Symptoms PROM - Programmable Read Only Memory: Customer Interest PCM - DTC U1016 Stored With No Symptoms File In Section: 6E - Engine Fuel & Emission Bulletin No.: 87-65-19 Date: May, 1998 Subject: DTC U1016, Stored Code with No Active Symptoms (Reprogram PCM) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L, 2.4L Engine (VINs 4, T - RPOs LN2, LD9) with Automatic Transmission Only Condition During diagnosis for various unrelated conditions, a DTC U1016 may be noted as stored in the PCM with no active symptoms. If there were an actual failure, this code would be accompanied by a similar code in the IP cluster or in each of the devices on the UART line. Cause A calibration error may induce the PCM to store DTC U1016 as an inactive stored history code during vehicle key-down. Correction If during diagnostics for other conditions, a DTC U1016 is noted without any symptoms that are part of the parameter for setting the U1016 code, reprogram the PCM with the appropriate calibration from the list. These calibrations are available on 1998 CD-ROM # 9 and later versions. Service Procedure 1. Install a scan tool and verify that the previously noted DTC is set. 2. Note the calibration ID currently in the PCM. 3. Reprogram the PCM with the Calibration Number listed in the table. 4. Operate the vehicle and check for any additional DTC's. 5. If the vehicle exhibits a U1016 code after being reprogrammed, review the appropriate Service Manual diagnostic procedures. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 87-65-19 > May > 98 > PCM - DTC U1016 Stored With No Symptoms > Page 5930 Use the correct calibration from the list. Warranty Information For vehicles repaired under warranty, use table: Labor Operation Description Labor Time J6355 PROM-Reprogramming 0.4 hr * Diagnosis time may be claimed for 0.0 to 0.3 hour depending on actual time performing diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-25A > Mar > 98 > PROM - Hesitation, Sag, Stall When Cold PROM - Programmable Read Only Memory: Customer Interest PROM - Hesitation, Sag, Stall When Cold File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-25A Date: March, 1998 Subject: Hesitation, Sag, or Engine Stall During Cold Driveaway Maneuver (Reprogram PCM) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) and Automatic Transmission (MD9, MN4) Vehicles Involved: Involved are Certain 1998 J-Car Models Equipped with the 2.2L (RPO LN2) VIN Engine Code 4 Engine, that Fall within the VIN Breakpoints: This bulletin is being revised to update calibration information. Please discard Corporate Bulletin Number 77-5-25 (Section 6E - Engine Fuel & Emission). Condition Some vehicles may exhibit a hesitation, engine sag, or an engine stall during light acceleration (30 percent throttle or less) when the engine is cold. This condition may be more noticeable when the ambient temperature is less than 10°C (50°F). Cause Certain fuels in combination with variations in manufacturing may allow some cars to run leaner under certain conditions. Correction Reprogram the PCM with the revised calibration that takes into account the above conditions. These calibrations are available on 1997 CD-ROM # 19 and later versions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-25A > Mar > 98 > PROM - Hesitation, Sag, Stall When Cold > Page 5935 Calibration Numbers Use the correct calibration from the list as shown. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J6355 Reprogram PCM 0.4 hr (on car) J6352 Reprogram PCM 0.4 hr (off car) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5941 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5942 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 87-65-19 > May > 98 > PCM - DTC U1016 Stored With No Symptoms PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - DTC U1016 Stored With No Symptoms File In Section: 6E - Engine Fuel & Emission Bulletin No.: 87-65-19 Date: May, 1998 Subject: DTC U1016, Stored Code with No Active Symptoms (Reprogram PCM) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L, 2.4L Engine (VINs 4, T - RPOs LN2, LD9) with Automatic Transmission Only Condition During diagnosis for various unrelated conditions, a DTC U1016 may be noted as stored in the PCM with no active symptoms. If there were an actual failure, this code would be accompanied by a similar code in the IP cluster or in each of the devices on the UART line. Cause A calibration error may induce the PCM to store DTC U1016 as an inactive stored history code during vehicle key-down. Correction If during diagnostics for other conditions, a DTC U1016 is noted without any symptoms that are part of the parameter for setting the U1016 code, reprogram the PCM with the appropriate calibration from the list. These calibrations are available on 1998 CD-ROM # 9 and later versions. Service Procedure 1. Install a scan tool and verify that the previously noted DTC is set. 2. Note the calibration ID currently in the PCM. 3. Reprogram the PCM with the Calibration Number listed in the table. 4. Operate the vehicle and check for any additional DTC's. 5. If the vehicle exhibits a U1016 code after being reprogrammed, review the appropriate Service Manual diagnostic procedures. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 87-65-19 > May > 98 > PCM - DTC U1016 Stored With No Symptoms > Page 5951 Use the correct calibration from the list. Warranty Information For vehicles repaired under warranty, use table: Labor Operation Description Labor Time J6355 PROM-Reprogramming 0.4 hr * Diagnosis time may be claimed for 0.0 to 0.3 hour depending on actual time performing diagnosis. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 77-65-25A > Mar > 98 > PROM - Hesitation, Sag, Stall When Cold PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Hesitation, Sag, Stall When Cold File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-25A Date: March, 1998 Subject: Hesitation, Sag, or Engine Stall During Cold Driveaway Maneuver (Reprogram PCM) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) and Automatic Transmission (MD9, MN4) Vehicles Involved: Involved are Certain 1998 J-Car Models Equipped with the 2.2L (RPO LN2) VIN Engine Code 4 Engine, that Fall within the VIN Breakpoints: This bulletin is being revised to update calibration information. Please discard Corporate Bulletin Number 77-5-25 (Section 6E - Engine Fuel & Emission). Condition Some vehicles may exhibit a hesitation, engine sag, or an engine stall during light acceleration (30 percent throttle or less) when the engine is cold. This condition may be more noticeable when the ambient temperature is less than 10°C (50°F). Cause Certain fuels in combination with variations in manufacturing may allow some cars to run leaner under certain conditions. Correction Reprogram the PCM with the revised calibration that takes into account the above conditions. These calibrations are available on 1997 CD-ROM # 19 and later versions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 77-65-25A > Mar > 98 > PROM - Hesitation, Sag, Stall When Cold > Page 5956 Calibration Numbers Use the correct calibration from the list as shown. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J6355 Reprogram PCM 0.4 hr (on car) J6352 Reprogram PCM 0.4 hr (off car) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5973 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5974 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5980 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5981 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 5982 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5986 Brake Transaxle Shift Interlock (BTSI) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 5991 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Valve To Valve Body ......................................................................................................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle > Page 5997 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5998 Torque Converter Clutch Solenoid: Service and Repair REMOVAL PROCEDURE 1. Remove the valve body cover. Refer to Valve Body Cover Replacement. 2. Remove the transmission mount bracket. 3. Disconnect the solenoid wire harness from the case electrical connector. 4. Disconnect the wire leads from the pressure switch. 5. Remove the torque converter clutch solenoid bolt from the control valve body. 6. Remove the 3rd clutch pressure switch. 7. Remove the 2nd clutch pressure switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5999 1. Install the 2nd clutch pressure switch, if applicable. ^ Tighten to 12 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install 3rd clutch pressure switch. ^ Tighten to 12 Nm (124 inch lbs.). 3. Install the torque converter clutch solenoid bolt to the control valve body. 4. Install the 0-ring. ^ Tighten to 12 Nm (124 inch lbs.). 5. Connect the wire leads to the pressure switch. 6. Connect the solenoid wire harness to the case electrical connector. 7. Install the transmission mount bracket. 8. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 9. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6010 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6011 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6017 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6018 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6019 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6023 Brake Transaxle Shift Interlock (BTSI) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 6028 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Valve To Valve Body ......................................................................................................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle > Page 6034 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6035 Torque Converter Clutch Solenoid: Service and Repair REMOVAL PROCEDURE 1. Remove the valve body cover. Refer to Valve Body Cover Replacement. 2. Remove the transmission mount bracket. 3. Disconnect the solenoid wire harness from the case electrical connector. 4. Disconnect the wire leads from the pressure switch. 5. Remove the torque converter clutch solenoid bolt from the control valve body. 6. Remove the 3rd clutch pressure switch. 7. Remove the 2nd clutch pressure switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6036 1. Install the 2nd clutch pressure switch, if applicable. ^ Tighten to 12 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install 3rd clutch pressure switch. ^ Tighten to 12 Nm (124 inch lbs.). 3. Install the torque converter clutch solenoid bolt to the control valve body. 4. Install the 0-ring. ^ Tighten to 12 Nm (124 inch lbs.). 5. Connect the wire leads to the pressure switch. 6. Connect the solenoid wire harness to the case electrical connector. 7. Install the transmission mount bracket. 8. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 9. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6045 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6051 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6057 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6058 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6064 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Band Apply Servo: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6065 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Band Apply Servo: Specifications 3T40 Automatic Transaxle Intermediate Servo Cover .................................................................................................................... ....................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6068 Band Apply Servo: Specifications 4T40-E Automatic Transaxle Tube Assembly, Transmission Oil To Lo/Reverse Servo Cover-M6 x 1.0 x 19.0 (Qty 1) .................................................................. 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan. 4. Remove the lo and the reverse band servo cover bolts. 5. Remove the lo and the reverse band servo cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6071 6. Remove the lo and the reverse band servo snap ring. 7. Remove the reverse band servo cover seal. 8. Remove the reverse band servo piston seal. 9. Remove the lo and the reverse band servo piston. 10. Remove the 4th band servo piston inner spring. 11. Remove the lo and the reverse band servo piston pin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6072 12. Remove the lo and the reverse band servo piston spring. INSTALLATION PROCEDURE 1. Install the lo and the reverse band servo piston spring. 2. Install the lo and the reverse band servo piston pin. 3. Install the 4th band servo piston inner spring. 4. Install the lo and the reverse band servo piston. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6073 5. Install the reverse band servo piston seal. 6. Install the reverse band servo cover seal. 7. Install the lo and the reverse band servo snap ring. 8. Install the lo and the reverse band servo cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6074 9. Install the lo and the reverse band servo cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 10. Install the oil pan 11. Lower the vehicle. 12. Add transmission fluid. 13. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). 14. Inspect the fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6075 Band Apply Servo: Service and Repair Intermediate/4TH Servo Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the bottom pan. 4. Remove the 4th band servo cover bolts. 5. Remove the 4th band servo cover. 6. Remove the snap ring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6076 7. Remove the 4th band servo piston seal ring. 8. Remove the 4th band servo piston seal. 9. Remove the 4th band servo piston. 10. Remove the 4th band servo piston inner spring. 11. Remove the 4th band servo piston pin. 12. Remove the intermediate band servo piston spring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6077 1. Install the intermediate band servo piston spring. 2. Install the 4th band servo piston pin. 3. Install the 4th band servo piston inner spring. 4. Install the 4th band servo piston. 5. Install the 4th band servo piston seal. 6. Install the 4th band piston seal ring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 6078 7. Install the snap ring. 8. Install the 4th band servo cover. 9. Install the 4th band servo cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 10. Install the bottom pan. 11. Lower the vehicle. 12. Add transmission fluid 13. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). 14. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 87-71-66 > May > 98 > A/T Delayed/Slow or No Second to Third Gear Upshift Case: Customer Interest A/T - Delayed/Slow or No Second to Third Gear Upshift File In Section: 7 - Transmission Bulletin No.: 87-71-66 Date: May, 1998 Subject: Delayed, Slow or No Second to Third Gear Upshift (Replace the Case Cover Assembly or Transmission Assembly) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with HYDRA-MATIC 3T4O Transaxle/Transmission (RPO MD9) Condition Some owners outside of the recall population may comment on a delayed, slow or no second to third gear upshift. Cause This condition may be caused by a fluid pressure leak between the driven sprocket support and the case cover assembly. Correction To repair this condition the case cover assembly or the transmission assembly must be replaced. Service Information Procedure 1. Verify the customer concern. 2. Check the transmission fluid for proper level. 3. Use the fluid color chart to determine the appropriate repair procedure. Transmission Fluid Checking Procedure Diagnosing Transmission Fluid by Color - Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 87-71-66 > May > 98 > A/T Delayed/Slow or No Second to Third Gear Upshift > Page 6087 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 87-71-66 > May > 98 > A/T - Delayed/Slow or No Second to Third Gear Upshift Case: All Technical Service Bulletins A/T - Delayed/Slow or No Second to Third Gear Upshift File In Section: 7 - Transmission Bulletin No.: 87-71-66 Date: May, 1998 Subject: Delayed, Slow or No Second to Third Gear Upshift (Replace the Case Cover Assembly or Transmission Assembly) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with HYDRA-MATIC 3T4O Transaxle/Transmission (RPO MD9) Condition Some owners outside of the recall population may comment on a delayed, slow or no second to third gear upshift. Cause This condition may be caused by a fluid pressure leak between the driven sprocket support and the case cover assembly. Correction To repair this condition the case cover assembly or the transmission assembly must be replaced. Service Information Procedure 1. Verify the customer concern. 2. Check the transmission fluid for proper level. 3. Use the fluid color chart to determine the appropriate repair procedure. Transmission Fluid Checking Procedure Diagnosing Transmission Fluid by Color - Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 87-71-66 > May > 98 > A/T - Delayed/Slow or No Second to Third Gear Upshift > Page 6093 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 6094 Case: Specifications Manual Detent Spring Assembly To Case .................................................................................................................................................. 11 Nm (8 ft. lbs.) Parking Lock Bracket To Case ............................................................................................ ..................................................................... 24 Nm (18 ft. lbs.) Pipe Retainer To Case ..................... ......................................................................................................................................................... 24 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Case: Service and Repair 3T40 Automatic Transaxle REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the transmission bracket. 3. Remove the valve body cover. Refer to Valve Body Cover Replacement. 4. Disconnect the TCC wire from the case connector. 5. Remove the control valve body bolts. 6. Remove the control valve body from the oil pump. IMPORTANT: Do not lose the check balls. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6097 7. Remove the oil pump assembly bolts. 8. Remove the oil pump assembly from the case cover. 9. Remove the oil pump drive shaft. 10. Remove the control valve body spacer plate. 11. Remove the spacer plate gaskets. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6098 12. Remove the case cover bolts. 13. Remove the case cover. 14. Install two 12 x 1.95 x 14 bolts in the dowel pin holes and tighten equally in order to pull the case cover loose 15. Inspect the drive link assembly. Refer to Drive Link Assembly Replacement. INSTALLATION PROCEDURE 1. Install the case cover. 2. Install the case cover bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Install the check balls into the case cover. NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the spacer plate gaskets. 4. Install the control valve body spacer plate. 5. Install the oil pump drive shaft. 6. Install the check ball into the control valve assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6099 7. Install the oil pump assembly to the case cover. 8. Install the oil pump assembly bolts. 9. Install the control valve body to the oil pump. 10. Install the control valve body bolts. 11. Connect the TCC wire to the case electrical connector. 12. Install the valve body cover. Refer to Valve Body Cover Replacement. 13. Install the transmission mount bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6100 14. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6101 Case: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Install the J 28467-360 to the transmission. 3. Remove the air cleaner assembly. 4. Remove the upper transmission support assembly bolts. 5. Remove the upper side cover bolts. 6. Remove the transmission mount from the transmission. Refer to the appropriate procedure: ^ AT Mount Replacement (Front) ^ AT Mount Replacement (Rear) ^ AT Mount Replacement (Side) 7. Remove the transmission support from the transmission. Refer to A/T Mount Replacement (Side). 8. Remove the left outer tie rod from the steering knuckle assembly. Refer to Steering Knuckle Replacement in Suspension. 9. Remove the left ball joint from the steering knuckle assembly. Refer to Lower Ball Joint Replacement in Suspension. 10. Remove the brake caliper from the steering knuckle assembly. Refer to Brake Caliper Replacement in Disc Brakes. 11. Remove the drive axle from the transmission and the support. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6102 12. Remove the front suspension support brace bolts from the suspension support. 13. Remove the front suspension support brace. 14. Remove the oil cooler lines from the transmission. Refer to A/T Oil Cooler Pipes Replacement. 15. Remove the clips that attach the wire harness to the body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6103 16. Remove the left suspension support bolts. 17. Loosen the right suspension support bolts enough in order to remove the upper side cover. 18. Lower the vehicle. 19. Lower the transmission with the engine support fixture enough in order to remove the upper side cover. 20. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 21. Remove the lower side cover bolts and studs. 22. Remove the side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6104 23. Remove the side cover gasket. 24. Clean the case and the side cover gasket surfaces. INSTALLATION PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture 1. Install the side cover gasket. 2. Install the side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6105 3. Install the side cover lower bolts. ^ Tighten the bolts to 28 Nm (21 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the transmission support assembly. Refer to A/T Mount Replacement (Side). 5. Loosely install the lower transmission support assembly bolts. 6. Lower the vehicle. 7. Use the J 28467-360 in order to raise the transmission. 8. Install the side cover upper bolts. ^ Tighten the bolts to 28 Nm (21 ft. lbs.). 9. Install the transmission mount. Refer to the appropriate procedure: ^ AT Mount Replacement (Front) ^ AT Mount Replacement (Rear) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6106 ^ AT Mount Replacement (Side) 10. Attach the wire harness to the body. 11. Install the oil cooler lines to the transmission. Refer to A/T Oil Cooler Pipes Replacement. 12. Tighten the right front suspension support bolts. 13. Install the left front suspension support bolts. 14. Install the front suspension support brace. 15. Install the front suspension support brace bolts. 16. Install the drive axle to the transmission. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. 17. Install the left ball joint to the steering knuckle assembly. Refer to Lower Ball Joint Replacement in Suspension. 18. Install the left outer tie rod to the steering knuckle assembly. Refer to Steering Knuckle Replacement in Suspension. 19. Install the brake caliper to the steering knuckle assembly. Refer to Brake Caliper Replacement in Disc Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6107 20. Install the left splash shield. 21. Install the left wheel and tire assembly. Refer to Wheel Installation in Tires and Wheels. 22. Lower the vehicle. 23. Install the air cleaner assembly. 24. Remove the J 28467-360 from the transmission. 25. Connect the negative battery cable. ^ Tighten the bolt to 16 Nm (12 ft. lbs.). 26. Add transmission fluid. 27. Apply the brakes. Start the engine. Shift the transmission from R (Reverse) to D (Drive). 28. Install the transmission mount pipe expansion bolt. Refer to the appropriate procedure: ^ AT Mount Replacement (Front) ^ AT Mount Replacement (Rear) ^ AT Mount Replacement (Side) 29. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6116 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent > Page 6126 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6132 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 6138 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6147 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6148 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6154 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6155 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 03-07-30-006 > Mar > 03 > A/T - 4T40-E/4T45-T Engineering Changes Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-T Engineering Changes File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-006 Date: March, 2003 INFORMATION Subject: MN4 (4T40-E) MN5 (4T45-E) Engineering Changes Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1997 Oldsmobile Achieva 1997-1999 Oldsmobile Cutlass 1998-2002 Oldsmobile Intrigue 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1997-2003 Pontiac Grand Am with 4T40-E (MN4) or 4T45-E (MN5) Automatic Transmission Engineering changes have been incorporated into the MN4 and MN5 Reverse Clutch Housing and related parts beginning with transmission assemblies produced on December 4, 2002, Julian Date 02 338. Refer to the following list for the affected parts and a description of how each changed: The new Reverse Clutch Center Seal has a larger feed orifice. ^ The new Reverse Clutch Snap Ring is thicker and stiffer. ^ The new Reverse Housing Snap Ring Grove is wider to accommodate the thicker snap ring. Elimination of the Backing Plate Selectives. The new clutch assembly is built with only the thickest of the three previous selective backing plates. The new Reverse Wave Plate is stiffer. Notice: To maintain proper operating calibration of the transmission, determine which Reverse Clutch Housing, Center Seat, Snap Ring, Backing Plate and Wave Plate to use according to the Julian date on which the transmission was assembled. Failure to use these parts as instructed will cause improper function, shift feel, and possible transmission distress. The affected service kits include an instruction sheet that details the difference between the 1st and 2nd design center seals, and how to determine which to use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 00-07-30-013 > Jun > 00 > A/T - 4T40-E/4T45-E Forward Clutch Piston Change Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-E Forward Clutch Piston Change File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-013 Date: June, 2000 INFORMATION Subject: Forward Clutch Piston Change on 4T40-E/4T45-E Automatic Transaxles Models: 1998-2000 Chevrolet Cavalier, Malibu 1998-1999 Oldsmobile Cutlass 1999-2000 Oldsmobile Alero 1998-2000 Pontiac Sunfire 1999-2000 Pontiac Grand Am with 4T40-E or 4T45-E (RPOs MN4, MN5) Automatic Transaxle Starting with transmission Julian date 9058, the forward clutch piston was changed for ease of assembly in manufacturing. The pistons will have the same part number (24208641), and either one may be used for service. Above is a picture showing the old design (1), and the new design (2). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 03-07-30-006 > Mar > 03 > A/T - 4T40-E/4T45-T Engineering Changes Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-T Engineering Changes File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-006 Date: March, 2003 INFORMATION Subject: MN4 (4T40-E) MN5 (4T45-E) Engineering Changes Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1997 Oldsmobile Achieva 1997-1999 Oldsmobile Cutlass 1998-2002 Oldsmobile Intrigue 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1997-2003 Pontiac Grand Am with 4T40-E (MN4) or 4T45-E (MN5) Automatic Transmission Engineering changes have been incorporated into the MN4 and MN5 Reverse Clutch Housing and related parts beginning with transmission assemblies produced on December 4, 2002, Julian Date 02 338. Refer to the following list for the affected parts and a description of how each changed: The new Reverse Clutch Center Seal has a larger feed orifice. ^ The new Reverse Clutch Snap Ring is thicker and stiffer. ^ The new Reverse Housing Snap Ring Grove is wider to accommodate the thicker snap ring. Elimination of the Backing Plate Selectives. The new clutch assembly is built with only the thickest of the three previous selective backing plates. The new Reverse Wave Plate is stiffer. Notice: To maintain proper operating calibration of the transmission, determine which Reverse Clutch Housing, Center Seat, Snap Ring, Backing Plate and Wave Plate to use according to the Julian date on which the transmission was assembled. Failure to use these parts as instructed will cause improper function, shift feel, and possible transmission distress. The affected service kits include an instruction sheet that details the difference between the 1st and 2nd design center seals, and how to determine which to use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 00-07-30-013 > Jun > 00 > A/T - 4T40-E/4T45-E Forward Clutch Piston Change Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-E Forward Clutch Piston Change File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-013 Date: June, 2000 INFORMATION Subject: Forward Clutch Piston Change on 4T40-E/4T45-E Automatic Transaxles Models: 1998-2000 Chevrolet Cavalier, Malibu 1998-1999 Oldsmobile Cutlass 1999-2000 Oldsmobile Alero 1998-2000 Pontiac Sunfire 1999-2000 Pontiac Grand Am with 4T40-E or 4T45-E (RPOs MN4, MN5) Automatic Transaxle Starting with transmission Julian date 9058, the forward clutch piston was changed for ease of assembly in manufacturing. The pistons will have the same part number (24208641), and either one may be used for service. Above is a picture showing the old design (1), and the new design (2). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Page 6173 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check Differential: Technical Service Bulletins A/T - Revised Final Drive Pinion End Play Check File In Section: 7 - Transmission Bulletin No.: 77-71-79A Date: February, 1998 SERVICE MANUAL UPDATE Subject: Section 7-Transmission/Transaxle - Transfer Case Unit Repair Manual (TURM) - 4T40-E Final Drive Pinion End Play Check Specification Models: 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Cutlass 1997-98 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and 2.2L, 2.4L or 3.1L Engine (VINs 4, T, M RPOs LN2, LD9, L82) This bulletin is being revised to correct 1998 service manual page number. Please discard Corporate Bulletin Number 77-71-79 (Section 7 - Transmission). This bulletin contains the 1997 and 1998 TURM manual with revised art work for the final drive pinion end play check procedure. Replace these pages in your 1997 and 1998 TURM manual: 1997 - revised page is: 7A2B-57 1998 - revised page is: 7-754 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check > Page 6178 4T40-E AUTOMATIC TRANSAXLE UNIT REPAIR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check > Page 6179 AUTOMATIC TRANSAXLE 4T40-E Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Service and Repair Drive Chain: Service and Repair REMOVAL PROCEDURE ^ Remove the transmission mount. Refer to A/T Mount Replacement (Front) and A/T Mount Replacement (Rear). ^ Remove the transmission support. Refer to Transmission Replacement. ^ Remove the valve body cover. Refer to Valve Body Cover Replacement. ^ Remove the case cover. Refer to Case Cover Replacement. INSPECTION PROCEDURE 1. Remove the valve body cover. 2. Push the slack strand (bottom strand) of the drive link until all slack is removed at the following locations: ^ Midway between the sprockets. ^ At right angles to the drive link. 3. Use a crayon to mark on the bottom side of the drive link. 4. Push up in the same manner and put a second mark on the case. 5. Ensure that both marks are made from the point on the drive link. 6. Measure the distance between the two marks. 7. Replace the drive link if the distance exceeds 22.2 mm (7/8 inch). 8. Ensure that the three machined surfaces are flush with the machined surface of the case. The drive link measurement will be inaccurate if the surfaces are not flush. INSTALLATION PROCEDURE Install the valve body cover. 1. Install the case cover. Refer to Case Cover Replacement. 2. Install the valve body cover. Refer to Valve Body Cover Replacement. 3. Install the transmission support. Refer to Transmission Replacement. 4. Install the transmission mount. Refer to A/T Mount Replacement (Front) and A/T Mount Replacement (Rear). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6187 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6188 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6189 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6190 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 3T40 Automatic Transaxle Bottom Pan Removal ........................................................................................................................... ............................................... 3.8 Liters (4.0 Quarts) Complete Overhaul .............................................................................................................................. ............................................... 6.6 Liters (7.0 Quarts) Dry ....................................................................................................................................................... ............................................... 8.5 Liters (9.0 Quarts) 4T40-E Automatic Transaxle Bottom Pan Removal ........................................................................................................................... ............................................... 7.0 Liters (7.4 Quarts) Complete Overhaul .............................................................................................................................. ........................................... 10.0 Liters (10.6 Quarts) New Converter ..................................................................................................................................... ............................................... 2.5 Liters (2.6 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 6193 Fluid - A/T: Fluid Type Specifications DEXRON-III Automatic Transmission Fluid (or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6194 Checking Oil Level Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle Fluid - A/T: Testing and Inspection 3T40 Transaxle Transmission Fluid Level and Condition Check Important: When you check the fluid level, the fluid will be higher on the indicator when the transmission is cold. Conversely, the fluid level will drop when checked at operating temperature. This is due to the case thermostat element. 1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 88°-93°C (190°-200°F). 2. Park the vehicle on a level surface. Apply the parking brake and block the wheels. 3. While the engine is idling and with your foot on the brake, move the shift lever through each gear range, ending in Park. 4. Check the fluid level, color, and condition. 5. If you must add fluid, use DEXRON-III Automatic Transmission Fluid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 6197 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 6198 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 6199 Fluid - A/T: Testing and Inspection 4T40-E Transaxle Transmission Fluid Level and Condition Check (Diagnosis) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 6200 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 3T40 Transaxle > Page 6201 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid - A/T: Service and Repair 3T40 Automatic Transaxle Changing Oil and Filter REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place A drain . pan under the transmission Oil Pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the Oil Pan sealing surfaces. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6204 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6205 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 in. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Filler Tube Removal and Installation REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6206 1. Remove the oil level indicator. 2. Remove the nut or bolt that retains the fill tube to the mounting bracket. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a drain pan under the transmission. 5. Loosen the filler tube from the transmission. 6. Remove the filler tube seal. 7. Lower the vehicle. 8. Pull the tube out of the vehicle from the top. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6207 1. Install the filler tube through the top of the vehicle. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Install the filler tube seal into the transmission. Lubricate the seal with DEXRON(R) IIE, or DEXRON(R) III. 4. Install the filler tube into the transmission. 5. Lower the vehicle. 6. Install the nut that retains the tube to the mounting bracket. 7. Install the oil level indicator. 8. Adjust the oil level. Transaxle Fluid Flushing PREPARATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6208 ^ Tools Required J 35944-A Oil Cooler and Line Flusher - J 35944-20 Cooler Flushing Fluid Whenever you remove a transmission for service, do a transmission oil cooler flushing. It is essential to flush the oil cooler under the following conditions: ^ After a major overhaul ^ Suspected contamination ^ Pump or torque converter replacement For complete transmission service, perform the flush procedure after the overhauled or replacement assembly is installed in the vehicle. 1. Remove the fill cap on the J 35944-A. 2. Fill the can with 0.6 liter (20-21 ounces) of J 35944-20, or equivalent, cooler flushing fluid. Do not overfill. If you overfill, the tool will need recharging with air before the backflush. 3. Follow the manufacturer's suggested procedures for proper handling of the solution. IMPORTANT: Shop air supply must not exceed 825 kPa (120 psi), and must be equipped with a water/oil filter. 4. Secure the fill cap, and pressurize the flusher can with shop air to 550-700 kPa (80-100 psi). 5. Connect the J 35944-A to the transmission end of the transmission cooler pipe that feeds the bottom fitting of the oil cooler. 6. Connect the discharge hose to the top oil cooler pipe. 7. Clip the discharge hose to the oil drain container. 8. With the water valve on the tool in the OFF position, connect the water hose from the water supply to the tool. 9. Turn ON the water supply at the faucet. INITIAL FLUSHING IMPORTANT: If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 1. Switch the water valve on the tool to the ON position. Allow the water to flow through the oil cooler for 10 seconds in order to remove the transmission fluid in the system. 2. Switch the water valve on the tool to the OFF position. Clip the discharge hose onto a 5 gallon pail with a lid. If no lid is available, place a shop towel over the end of the hose in order to prevent splash. The discharge will foam vigorously when you introduce solution into the water stream. 3. Switch the water valve on the tool to the ON position. Depress the trigger that mixes the flushing solution into the water flow. Use the bale clip on the handle in order to hold down the trigger. 4. Flush the oil cooler with water and solution for 2 minutes. During the flush, attach the air supply to the air valve on the tool for 3-5 seconds after every 15-20 second interval in order to create a surging action. 5. Release the trigger. Switch the water valve on the tool to the OFF position. 6. Disconnect both hoses from the oil cooler pipes. BACKFLUSH 1. Connect the hoses to the oil cooler pipes in order to perform a backflush. 2. Switch water valve on the tool to the ON position. Depress the trigger in order to mix the flushing solution with the water flow. Use the bale clip on the handle to hold down the trigger. 3. Flush the oil cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve on the tool for 3-5 seconds after each 15-20 second interval in order to create a surging action. 4. Release the trigger. Allow water only to rinse the oil cooler for 1 minute. 5. Turn the water supply OFF at the faucet. 6. Attach the air supply to the air valve on the tool. Dry out the system with air for at least 2 minutes. Dry out the system longer than 2 minutes, if moisture from the oil cooler line discharge hose is visible. 7. Connect the cooler feed pipe to the transmission. The cooler feed is the bottom connection at the transmission. 8. If not already connected, attach the discharge hose to the cooler return pipe. Place the hose into an appropriate drain container. 9. After filling the transmission with DEXRON(R) III or DEXRON(R) IIE automatic transmission fluid, or equivalent, start the engine. Run the engine for 30 seconds. This removes any residual moisture from the oil cooler and the cooler pipes, protects all the components from corrosion, and checks the flow rate through the cooler. 10. You should get a minimum of 1.9 liters (2 quarts) of transmission fluid during this 30 second run. If the flow of fluid is insufficient, disconnect the oil cooler feed line at the radiator and restart the engine. 11. If the flow is insufficient, inspect the transmission for cause. Inspect the cooler pipes and fittings. Repeat the cooler flushing procedure. Replace the cooler if the flow is still insufficient. 12. Remove the discharge hose. 13. Reconnect the cooler return pipe to the transmission. 14. Refill the unit to the proper fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6209 Fluid - A/T: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure at Testing and Inspection. See: Testing and Inspection 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6210 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6211 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 in. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - PWM Filter Removal Fluid Filter - A/T: Technical Service Bulletins A/T - PWM Filter Removal File In Section: 07 - Transmission/Transaxle Bulletin No.: 00-07-30-016 Date: September, 2000 Subject: Removal Of The PWM Filter From The Spacer Plate - 4T40E/4T45E Automatic Transmission Models: 1998-2000 Chevrolet Cavalier, Malibu 1998-1999 Oldsmobile Cutlass 1999-2000 Oldsmobile Alero 1998-2000 Pontiac Sunfire 1999-2000 Pontiac Grand Am with 4T40E or 4T45E Automatic Transmission (RPOs MN4, MN5) The PWM filter (Item 17), which snaps into the spacer plate, has been eliminated. The use of a filter in this location is redundant. The PWM has its own filter located on the solenoid. Pictures of the spacer plate and the filter location on the spacer plate as shown. The PWM filter which was located in the spacer plate has been removed from GMSPO inventory and is no longer available. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid Filter - A/T: Service and Repair 3T40 Automatic Transaxle A/T Fluid/Filter Changing (Remove) PREPARATION ^ Tools Required J 35944-A Oil Cooler and Line Flusher - J 35944-20 Cooler Flushing Fluid Whenever you remove a transmission for service, do a transmission oil cooler flushing. It is essential to flush the oil cooler under the following conditions: ^ After a major overhaul ^ Suspected contamination ^ Pump or torque converter replacement For complete transmission service, perform the flush procedure after the overhauled or replacement assembly is installed in the vehicle. 1. Remove the fill cap on the J 35944-A. 2. Fill the can with 0.6 liter (20-21 ounces) of J 35944-20, or equivalent, cooler flushing fluid. Do not overfill. If you overfill, the tool will need recharging with air before the backflush. 3. Follow the manufacturer's suggested procedures for proper handling of the solution. IMPORTANT: Shop air supply must not exceed 825 kPa (120 psi), and must be equipped with a water/oil filter. 4. Secure the fill cap, and pressurize the flusher can with shop air to 550-700 kPa (80-100 psi). 5. Connect the J 35944-A to the transmission end of the transmission cooler pipe that feeds the bottom fitting of the oil cooler. 6. Connect the discharge hose to the top oil cooler pipe. 7. Clip the discharge hose to the oil drain container. 8. With the water valve on the tool in the OFF position, connect the water hose from the water supply to the tool. 9. Turn ON the water supply at the faucet. INITIAL FLUSHING IMPORTANT: If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 1. Switch the water valve on the tool to the ON position. Allow the water to flow through the oil cooler for 10 seconds in order to remove the transmission fluid in the system. 2. Switch the water valve on the tool to the OFF position. Clip the discharge hose onto a 5 gallon pail with a lid. If no lid is available, place a shop towel over the end of the hose in order to prevent splash. The discharge will foam vigorously when you introduce solution into the water stream. 3. Switch the water valve on the tool to the ON position. Depress the trigger that mixes the flushing solution into the water flow. Use the bale clip on the handle in order to hold down the trigger. 4. Flush the oil cooler with water and solution for 2 minutes. During the flush, attach the air supply to the air valve on the tool for 3-5 seconds after every 15-20 second interval in order to create a surging action. 5. Release the trigger. Switch the water valve on the tool to the OFF position. 6. Disconnect both hoses from the oil cooler pipes. BACKFLUSH 1. Connect the hoses to the oil cooler pipes in order to perform a backflush. 2. Switch water valve on the tool to the ON position. Depress the trigger in order to mix the flushing solution with the water flow. Use the bale clip on the handle to hold down the trigger. 3. Flush the oil cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve on the tool for 3-5 seconds after each 15-20 second interval in order to create a surging action. 4. Release the trigger. Allow water only to rinse the oil cooler for 1 minute. 5. Turn the water supply OFF at the faucet. 6. Attach the air supply to the air valve on the tool. Dry out the system with air for at least 2 minutes. Dry out the system longer than 2 minutes, if moisture from the oil cooler line discharge hose is visible. 7. Connect the cooler feed pipe to the transmission. The cooler feed is the bottom connection at the transmission. 8. If not already connected, attach the discharge hose to the cooler return pipe. Place the hose into an appropriate drain container. 9. After filling the transmission with DEXRON(R) III or DEXRON(R) IIE automatic transmission fluid, or equivalent, start the engine. Run the engine for 30 seconds. This removes any residual moisture from the oil cooler and the cooler pipes, protects all the components from corrosion, and checks the flow rate through the cooler. 10. You should get a minimum of 1.9 liters (2 quarts) of transmission fluid during this 30 second run. If the flow of fluid is insufficient, disconnect the oil cooler feed line at the radiator and restart the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6218 11. If the flow is insufficient, inspect the transmission for cause. Inspect the cooler pipes and fittings. Repeat the cooler flushing procedure. Replace the cooler if the flow is still insufficient. 12. Remove the discharge hose. 13. Reconnect the cooler return pipe to the transmission. 14. Refill the unit to the proper fluid level. A/T Fluid/Filter Changing (Install) REMOVAL PROCEDURE 1. Remove the oil level indicator. 2. Remove the nut or bolt that retains the fill tube to the mounting bracket. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Place a drain pan under the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6219 5. Loosen the filler tube from the transmission. 6. Remove the filler tube seal. 7. Lower the vehicle. 8. Pull the tube out of the vehicle from the top. INSTALLATION PROCEDURE 1. Install the filler tube through the top of the vehicle. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Install the filler tube seal into the transmission. Lubricate the seal with DEXRON(R) IIE, or DEXRON(R) III. 4. Install the filler tube into the transmission. 5. Lower the vehicle. 6. Install the nut that retains the tube to the mounting bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6220 7. Install the oil level indicator. 8. Adjust the oil level. A/T Fluid/Filter Changing (F/F Changing) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place A drain . pan under the transmission Oil Pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the Oil Pan sealing surfaces. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6221 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6222 4. Install a new oil pan gasket. 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6223 Fluid Filter - A/T: Service and Repair 4T40-E Automatic Transaxle Oil Filter and Seal Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Drain the transmission oil. Refer to A/T Fluid/Filter Changing. 3. Remove the oil pan attaching bolts and the oil pan. 4. Remove the gasket. 5. Remove the oil filter assembly. 6. Remove the filter neck seal from the transmission case. Use a small screwdriver. Do not to score the case during removal. Discard the filter seal, it is not reusable. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6224 1. Install the new oil filter neck seal. Tap gently and evenly on the seal in order to prevent damage to the case bore or the seal. 2. Install the new oil filter. 3. Install the oil pan gasket and the oil pan. Use a new gasket if the sealing rings are damaged. 4. Install the oil pan attaching bolts. ^ Tighten the bolts to 14 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) III oil. 7. Inspect the oil pan gasket for leaks. A/T Fluid/Filter Changing REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carefully in order to prevent damage to the transmission case or the oil pan sealing surfaces. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6225 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain. 6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure (Diagnosis). 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) Transmission Assembly Lubricant NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6226 1. Coat the seal with a small amount of J 36850 or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. 5. Install the oil pan. 6. Install the oil pan bolts. ^ Tighten the bolts to 10 Nm (89 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6227 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) III oil. 11. Adjust the cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6232 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6233 Fluid Line/Hose: Technical Service Bulletins Transaxle Cooler Line - Seal Installation Procedure File In Section: 7 - Transmission Bulletin No.: 87-71-67 Date: June, 1998 INFORMATION Subject: Transaxle Cooler Line Seal Installation Procedure Models: 1995-98 Chevrolet Cavalier 1997-98 Chevrolet Malibu 1997-98 Oldsmobile Cutlass 1999 Oldsmobile Alero 1995-98 Pontiac Sunfire 1999 Pontiac Grand Am with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) or 4T45-E Transaxle RPO MN5) and 2.2L, 2.4L, 3.1 L, 3.4L Engine VINs 4, T, M, E - RPOs LN2, LD91 L821 LA1) This bulletin contains information regarding the installation of cooler line seals into the case of either a 4T40-E or 4T45-E transaxle. Seal Installation Procedure (Figure 1) To prevent automatic transmission fluid from leaking from the cooler line seals (49) after installing new seals, perform the following procedure. Important: Only GM Goodwrench DEXRON(R) III automatic transmission fluid should be used as part of warranty repair of GM Powertrain automatic transmissions. Notice: Failure to lubricate the cooler line seals (49) with automatic transmission fluid DEXRON(R) III, before installing the cooler line pipes into the seals, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6234 may cause damage to the seals. 1. Lubricate the inside surface of both new cooler line seals (49) with automatic transmission fluid DEXRON(R) III. 2. Place a new cooler line seal (49) into the case bore. 3. Install the cooler line seal installer tool J 41239-1 on the transmission case (51) at the cooler line bracket bolt hole. 4. Press the new cooler line seal (49) in by tightening the seal pressing bolt on the cooler line seal installer tool J 41239-1 until the seal bottoms out in the case bore. 5. Repeat steps 2 through 4 for the second cooler line seal (49). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Line/Hose: Specifications 3T40 Automatic Transaxle Line Pressure Take-off ........................................................................................................................ ....................................................... 11 Nm (8 ft. lbs.) Cooler Pipes At Case ....................................... ......................................................................................................................................... 22 Nm (16 ft. lbs.) Cooler Pipes At Radiator ......................................................................................................... ................................................................. 27 Nm (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6237 Fluid Line/Hose: Specifications 4T40-E Automatic Transaxle Cooler Pipes At Case .......................................................................................................................... .................................................... 8 Nm (71 inch lbs.) Cooler Pipes At Radiator ................................. .............................................................................................................................. 20-40 Nm (15-30 ft. lbs.) Oil Feed Tube Bolts ................................................................................................................. ........................................................... 14 Nm (124 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid Line/Hose: Service and Repair 3T40 Automatic Transaxle NOTICE: Allow sufficient clearance around transmission oil cooler pipes in order to prevent damage or wear which may cause fluid loss. If replacement of the transmission oil cooler pipes is required, use only double-wrapped and brazed steel pipe meeting GM specification 123M, or equivalent. The pipe should be double-flared. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6240 Fluid Line/Hose: Service and Repair 4T40-E Automatic Transaxle Oil Cooler Pipe Seals Replacement REMOVAL PROCEDURE ^ Tools Required J 41239-2 Cooler Pipe Seal Remover - J 6125-1B Slide Hammer - J 6471 Slide Hammer Adapter 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil cooler lines from the transmission. Refer to A/T Oil Cooler Pipes Replacement. 3. Install the J 41239-2 into the cooler line seal. 4. Remove the oil cooler line seals. Use the J 6125-1B and the J 6471. INSTALLATION PROCEDURE ^ Tools Required: J 41239-1 Cooler Pipe Seal Installer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6241 1. Install the J 41239-1 on the transmission case using cooler line bracket bolt. 2. Install a new seal in the case bore. 3. Press the new seals in. Tighten the cooler line bracket bolt until the seal bottoms out in the case bore. 4. Install the transmission oil cooler lines. Refer to A/T Oil Cooler Pipes Replacement. 5. Lower the vehicle. 6. Inspect the fluid level. A/T Oil Cooler Pipes Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil cooler lines from the radiator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6242 3. Remove the transmission oil cooler line bracket bolt from the transmission. 4. Remove the transmission oil cooler lines from the vehicle. INSTALLATION PROCEDURE 1. Install the transmission oil cooler lines to the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6243 2. Install the transmission oil cooler line bracket bolt to the transmission. ^ Tighten the bracket bolt to 8 Nm (71 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the transmission oil cooler lines to the radiator. ^ Tighten the pipe fitting to 20-40 Nm (115-30 ft. lbs.). 4. Lower the vehicle. 5. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pan: Specifications 3T40 Automatic Transaxle Oil Pan Bolts ........................................................................................................................................ ....................................................... 10 Nm (89 in.lb) Oil Pan And Valve Body Cover ......................... ............................................................................................................................................ 11 Nm (8 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6248 Fluid Pan: Specifications 4T40-E Automatic Transaxle Oil Pan Attaching Bolts ........................................................................................................................ ..................................................... 14 Nm (124 in.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 6249 Fluid Pan: Service and Repair REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Loosen the oil pan bolts. 3. Drain the oil. Use a suitable container to catch the transmission oil fluid. 4. Remove the oil pan attaching bolts. 5. Remove the oil pan. 6. Remove the oil pan gasket. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 6250 1. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged. 2. Install the oil pan. 3. Install the oil pan attaching bolts. ^ Tighten the bolts to 14 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Lower the vehicle. 5. Refill the transmission to the proper level with DEXRON(R) III. 6. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6255 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 6256 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring > Page 6261 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 6262 Fluid Pump: Specifications Pump Cover To Case Cover ............................................................................................................... ...................................................... 24 Nm (18 ft. lbs.) Pump Cover To Valve Body ............................ ........................................................................................................................................... 11 Nm (8 ft. lbs.) Pump Cover To Valve Body .................................................................................................... ................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications Governor: Specifications Speedometer Driven Gear To Governor Cover ....................................................................................................................................... 9 Nm (75 inch lbs.) Governor Cover To Case ..................................................................................................... ....................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 6266 Governor: Service and Repair REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the Vehicle Speed Sensor (VSS) assembly. Refer to Vehicle Speed Sensor Replacement. 3. Remove the governor. 4. Remove the governor compression ring. 5. Remove the governor shaft seal. 6. Remove the governor shaft bushing and the screen. INSTALLATION PROCEDURE 1. Install the governor shaft bushing and the screen. 2. Install the governor shaft seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 6267 3. Install the governor compression ring. 4. Install the governor. 5. Install the Vehicle Speed Sensor (VSS) assembly. Refer to Vehicle Speed Sensor Replacement. 6. Lower the vehicle. 7. Adjust the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Hydraulic Thermo Valve, A/T > Component Information > Service and Repair Hydraulic Thermo Valve: Service and Repair REMOVAL PROCEDURE 1. Remove the transmission mount. Refer to A/T Mount Replacement (Front) and A/T Mount Replacement (Rear). 2. Remove the transmission mount bracket. 3. Remove the valve body cover. Refer to Valve Body Cover Replacement. 4. Remove the case cover. Refer to Case Cover Replacement. 5. Inspect the thermo element washers. 6. Inspect the thermo element. 7. Inspect the thermo element plate. INSTALLATION PROCEDURE 1. Install the case cover. Refer to Case Cover Replacement 2. Install the valve body cover. Refer to Valve Body Cover Replacement. 3. Install the transmission mount bracket. 4. Install the transmission mount. Refer to A/T Mount Replacement (Front) and A/T Mount Replacement (Rear). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 6275 Output Shaft: Service and Repair REMOVAL PROCEDURE ^ Tools Required J 38868 Shaft Removal Tool - J 41227 Axle Shaft Sleeve Removal Tool - J 6125-1B Slide Hammer 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the drive axle assembly. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. 3. Remove the stub shaft from the transmission. Use the J 38868 and the J 6125-1B. 4. Remove the snap rings from the stub shaft. Discard the snap rings, these are not reusable. 5. Remove the sleeve from the stub shaft. Use the J 41227. 6. Inspect the sleeve for excessive wear, scratches or nicks that may cause a leak or damage to the seal portion. Replace the sleeve if it appears to be damaged. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 6276 ^ Tools Required J 41228 Stub Shaft Sleeve Installer 1. Install a new sleeve on the stub shaft. Use the J 41228. Install the J 41228 so that the collar is in the snap ring groove. 2. Install the two new snap rings on the stub shaft. 3. Add Polyurea grease to the splines of the output shaft in order to prevent damage to the shaft splines during vehicle operation. 4. Install the stub shaft into the transmission assembly. 5. Install the drive axle assembly. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. 6. Lower the vehicle. 7. Inspect the shaft sleeve for leaks. 8. Verify the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 Automatic Transaxle Parking Lock Cable: Adjustments 3T40 Automatic Transaxle PARK LOCK CABLE ADJUSTMENT 1. Place the floor shift lever in the P (Park) position. 2. Turn the column lock cylinder to the Lock position. 3. Unseat the body housing lock from the body housing. IMPORTANT: ^ No gap may exist between the metal terminal stop and the protruding end of the blue plastic collar. If a gap does exist between the terminal stop and the collar, adjust the position of the park lock cable. ^ The blue plastic collar must be flush or recessed about 1 mm (0.04 inch) within the ignition park lock housing. If the blue plastic collar is not in the proper location, adjust the position of the park lock cable. 4. Adjust the outer cable conduit in order to obtain the proper location for the white plastic housing in the ignition switch. Ensure that the body housing is still attached to the shift control mounting bracket. 5. Seat the body housing lock in the body housing while holding the outer cable conduit in position. 6. Inspect the park/lock control cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 Automatic Transaxle > Page 6281 Parking Lock Cable: Adjustments 4T40-E Automatic Transaxle PARK LOCK CABLE ADJUSTMENT 1. Place the floor shift lever in the P (Park) position. 2. Turn the column lock cylinder to the Lock position. 3. Unseat the body housing lock from the body housing. IMPORTANT: ^ No gap may exist between the metal terminal stop and the protruding end of the white plastic collar. If a gap does exist between the terminal stop and the collar, adjust the position of the park lock cable. ^ The white plastic collar must be flush or recessed about 1 mm (0.04 inch) within the ignition park lock housing. If the white plastic collar is not in the proper location, adjust the position of the park lock cable. 4. Adjust the outer cable conduit in order to obtain the proper location for the white plastic housing in the ignition switch. Ensure that the body housing is still attached to the shift control mounting bracket. 5. Seat the body housing lock in the body housing while holding the outer cable conduit in position. 6. Inspect the park/lock control cable. Refer to Park Lock Cable Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6282 Parking Lock Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 3. Remove the left sound insulator. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 4. Remove the knee bolster. 5. Loosen the lower steering column bracket bolts. 6. Lower the steering column. 7. Place the transmission shift lever in the P (Park) position. 8. Turn the ignition key to the RUN position. IMPORTANT: Do not proceed to the next step with the key in any other position. 9. Insert a screwdriver blade into the slot provided in the ignition switch inhibitor. 10. Depress the cable latch. Pull the control cable from the inhibitor. 11. Push the cable connector lock button at the shifter base to the up position. 12. Snap the cable from the park/lock lever pin. 13. Depress the two cable latches. Remove the control cable latches from the automatic transmission control. 14. Remove the control cable clips. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6283 1. Ensure that the cable lock button is in the up position. Place the shift lever in P (Park). IMPORTANT: When installing a new park/lock cable, keep the shipping cover gauge attached until you are instructed to detach it. The shipping cover gauge will aid in the proper positioning of the cable. 2. Snap the control cable connector into the automatic transmission control. 3. Place the ignition key in the RUN position. 4. Snap the control cable into the inhibitor housing until the snap lock is seated. IMPORTANT: Do not insert the cable with the key in any other position. 5. Remove the shipping cover gauge. 6. Turn the key to the LOCK position. 7. Snap the control cable end onto the shift park/lock lever pin. 8. Push the cable connector hose forward in order to remove any slack. 9. With no load applied to the connector nose, snap the cable connector lock button down. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6284 10. Raise and connect the steering column. IMPORTANT: Test for proper operation of the park/lock control cable before installing the steering column to the instrument panel. 11. Tighten the lower steering column bracket bolts. 12. Install the knee bolster. 13. Install the left sound insulator. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 14. Install the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 15. Connect the negative battery cable. INSPECTION PROCEDURE IMPORTANT: ^ No gap may exist between the metal terminal stop and the protruding end of the white plastic collar. If a gap does exist between the terminal stop and the collar, adjust the position of the park lock cable. ^ The white plastic collar must be flush or recessed about 1 mm (0.04 inch) within the ignition park lock housing. If the white plastic collar is not in the proper location, adjust the position of the park lock cable. 1. Ensure that the terminal stop on the column end of the park/lock cable is touching the white collar that protrudes from the ignition switch. Complete the following steps in order to inspect: 1.1. Turn the column lock cylinder to the LOCK position. 1.2. Place the floor shift lever into the P (Park) position. 1.3. Verify the correct position of the terminal stop. 2. Ensure that the column lock cylinder remains in the Lock position. 3. Ensure that the floor shift lever remains in the P (Park) position. 4. Gently depress the park/lock button on the floor shift lever until resistance is felt. 5. Verify that the white plastic collar travels no more than 1.5 mm (0.06 inch). The floor shift lever must not come out of P (Park). 6. With the column lock cylinder On, verify proper movement of the floor shift lever through all of the gear selections. 7. While moving the floor shift lever through all of the drive gears, verify that the column lock cylinder cannot be turned to the Lock position. IMPORTANT: Five inspections are used in order to verify proper installation. The installation must pass all 5 tests. If one or more of the tests fail, adjust the park/lock cable. Refer to Park Lock Cable Adjustment. 8. Ensure that the key can be removed with the column lock cylinder in the Lock position and the floor shift lever in the P (Park) position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > Page 6289 Parking Pawl: Service and Repair REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil pan and the oil pan gasket. 3. Remove the oil pan filter and the seal. 4. Remove the transmission fluid level indicator stop bracket. 5. Remove the spring shaft retainer. 6. Remove the parking pawl actuator bracket. 7. Remove the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > Page 6290 8. Remove the manual shift shaft pin. 9. Remove the manual valve with the retainer rod. 10. Remove the manual valve pin. 11. Remove the parking pawl spring. INSTALLATION PROCEDURE 1. Install the parking pawl spring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > Page 6291 2. Install the manual valve pin. 3. Install the manual valve with the retainer rod. 4. Install the manual shift shaft pin. 5. Install the clip. 6. Install the parking pawl actuator bracket. 7. Install the spring shaft retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > Page 6292 8. Install the transmission fluid level indicator stop bracket. 9. Install the oil pan filter,and the seal. 10. Install the oil pan and the gasket. 11. Lower the vehicle. 12. Adjust the oil level. 13. Inspect the shift linkage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6301 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6302 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6308 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6309 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6310 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6319 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6325 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Positive: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6331 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6332 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6333 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 6334 Seals and Gaskets: Service and Repair REMOVAL PROCEDURE ^ Tools Required J 6125-IB Slide Hammer - J 23129 Axle Seal Remover 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 3. Remove the inner splash shield. 4. Remove the tie rod from the steering knuckle. Refer to Steering Knuckle Replacement in Suspension. 5. Remove the ball joint from the steering knuckle. Refer to Lower Ball Joint Replacement in Suspension. 6. Remove the drive axle. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. 7. Remove the seals. Use the J 23129 and the J 6125-1B. IMPORTANT: Do not damage the seal bore. INSTALLATION PROCEDURE ^ Tools Required J 34115 Axle Seal Installer 1. Install the new oil seals. Use the J 34115. 2. Lubricate the seal lip with a light wipe of transmission oil. 3. Install the drive axle into the transmission case. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. IMPORTANT: Carefully guide the axle shaft past the lip seal. Do not allow the shaft splines to contact any portion of the seal lip surface because damage may occur. 4. Install the ball joint to the steering knuckle. Refer to Lower Ball Joint Replacement in Suspension. 5. Install the tie rod to the steering knuckle. Refer to Steering Knuckle Replacement in Suspension. 6. Seat the drive axle into the transmission case. 7. Install the tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 8. Lower the vehicle. 9. Inspect the oil seal for leaks. 10. Adjust the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6340 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 6341 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6350 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6351 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6357 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6358 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit Function/Installation Trunk / Liftgate Latch: All Technical Service Bulletins Trap Resistant Trunk Kit Function/Installation File In Section: 08 - Body and Accessories Bulletin No.: 99-08-66-002A Date: January, 2000 Subject: Trap Resistant Rear Compartment (Trunk) Kit Models: 1990-2000 Passenger Cars with Rear Compartments Except: 1990-1991 Buick Reatta 2000 Buick LeSabre 1990-1993 Cadillac Allante, Fleetwood Brougham 1997-2000 Cadillac Seville 2000 Cadillac Deville 1990 Chevrolet Caprice 1990-1991 Chevrolet Cavalier 1990-1996 Chevrolet Beretta 1990-2000 Chevrolet Metro, Prizm 1998-2000 Chevrolet Corvette 2000 Chevrolet Impala 1990-1992 Oldsmobile Toronado/Trofeo 1990-1991 Pontiac Sunbird 1990-1993 Pontiac LeMans 2000 Pontiac Bonneville This bulletin is being revised to add additional models and new part numbers. Please discard Corporate Bulletin Number 99-O8-66-002 (Section 08 - Body and Accessories). The purpose of this bulletin is to inform dealership personnel about the Trap Resistant Rear Compartment (Trunk) Kit, including the system function, necessary vehicle modifications and part numbers required to install the kit. The Trap Resistant Rear Compartment kit is composed of three main system components; one of which (the Rear Seat Tether), may or may not be needed, depending on the vehicle being retrofit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit Function/Installation > Page 6364 The first component of the kit is the illuminated Interior Release Handle (1). The Release Handle is mounted inside the rear compartment to the deck lid. This handle was designed so that a small child trapped in the rear compartment could use it to open the deck lid. The handle operates the deck lid latch mechanically, but is illuminated with two LED's when the deck lid is closed. The handle remains illuminated for a period of about one hour after the deck lid is closed. The LED's create a small parasitic load that will not drain the vehicle battery with normal usage. The second component of the kit is the Trap Resistant Latch (2). the Trap Resistant Latch is a modified deck lid latch designed to help prevent a child from unintentionally closing and latching the deck lid. The Trap Resistant Latch opens the rear compartment normally through all current means (key, RKE or passenger compartment release) but cannot be re-latched without the user performing a reset function. This reset function consists of pushing up on a small knob (3), while simultaneously pushing a slide mechanism to the right (4). Once the slide mechanism is fully pushed over, the small knob can be released. This function is a simple on-hand operation for an adult, but is difficult for a young child to perform. If the latch is not enabled, the deck lid will not latch and the rear compartment will not close. The third component is the Rear Seat Tether Kit. If the vehicle is equipped with a pass-through to the rear compartment and the folding rear seat can be unlatched from within the passenger compartment without the use of a key or other unlocking feature, then a Rear Seat Tether must be installed. This tether helps prevent a child from gaining access to the rear compartment of a vehicle from the passenger compartment by allowing a secondary lock of the seatback. The Rear Seat Tether employs one or two tethers (one per folding seatback), each permanently connected to a T-handle anchor mounted in the rear compartment. To lock the folding seatback, the user can partially fold the seatback and attach the tether to another T-handle anchor mounted to the seatback. When the tether is affixed to both T-handle anchors, the seat cannot be folded down. To fold down the seatback, the tether must be removed from the anchor attached to the seatback. Important: Installation of the Trap Resistant Latch on some vehicles may require sheet metal and/or trim modifications to the rear compartment striker area. These modifications should be communicated with the customer prior to installations. Also, installation of the Trap Resistant Latch requires a rear compartment lid "ajar" switch. Prior to ordering the Trap Resistant Rear Compartment Kit, inspect the old deck lid latch to see if it is equipped with an "ajar" switch. If the vehicle is not equipped with this switch, P/N 12506174 must be ordered. After completing the Trap Resistant Rear Compartment Kit installation, provide the customer with the supplemental Owner's Manual insert included in the kit and demonstrate the system function. This program is specially structured for a single purchase price to the owner. The owner is responsible to pay a maximum of $50.00 U.S.; $80.00 Canadian for parts and labor to install the complete Trap Resistant Rear Compartment Kit and Rear Seat Tether(s), if required. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit Function/Installation > Page 6365 Parts are currently available from GMSPO. Labor Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch: All Technical Service Bulletins Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 6370 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 83-15-15 > Aug > 98 > Rear Lid Latch - Revised Procedure for Replacement Trunk / Liftgate Latch: All Technical Service Bulletins Rear Lid Latch - Revised Procedure for Replacement File In Section: 10 - Body Bulletin No.: 83-15-15 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-8 - Revised Remove and Install Procedure for Rear Compartment Lid Latch Assembly to Add Spacer Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for rear compartment lid latch assembly (to add spacer for convertible only) in Section 10-8 of the Service Manual. Rear compartment Lid Latch Assembly Remove or Disconnect 1. Rear compartment lid latch cable assembly. 2. Unclip cable door at top of rear compartment lock release box. 3. Rear compartment lid remote release cable from lock release box. 4. Rear compartment lid latch assembly bolts. 5. Rear compartment lid latch assembly. 6. Rear compartment lid latch assembly spacer (convertible only). Install or Connect 1. Rear compartment lid latch assembly spacer (convertible only). 2. Rear compartment lid latch assembly. 3. Rear compartment lid latch assembly bolts. 4. Rear compartment lid remote release cable to lock release box. 5. Clip cable door at top of rear compartment lock release box. 6. Rear compartment lid latch cable assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit Function/Installation > Page 6380 The first component of the kit is the illuminated Interior Release Handle (1). The Release Handle is mounted inside the rear compartment to the deck lid. This handle was designed so that a small child trapped in the rear compartment could use it to open the deck lid. The handle operates the deck lid latch mechanically, but is illuminated with two LED's when the deck lid is closed. The handle remains illuminated for a period of about one hour after the deck lid is closed. The LED's create a small parasitic load that will not drain the vehicle battery with normal usage. The second component of the kit is the Trap Resistant Latch (2). the Trap Resistant Latch is a modified deck lid latch designed to help prevent a child from unintentionally closing and latching the deck lid. The Trap Resistant Latch opens the rear compartment normally through all current means (key, RKE or passenger compartment release) but cannot be re-latched without the user performing a reset function. This reset function consists of pushing up on a small knob (3), while simultaneously pushing a slide mechanism to the right (4). Once the slide mechanism is fully pushed over, the small knob can be released. This function is a simple on-hand operation for an adult, but is difficult for a young child to perform. If the latch is not enabled, the deck lid will not latch and the rear compartment will not close. The third component is the Rear Seat Tether Kit. If the vehicle is equipped with a pass-through to the rear compartment and the folding rear seat can be unlatched from within the passenger compartment without the use of a key or other unlocking feature, then a Rear Seat Tether must be installed. This tether helps prevent a child from gaining access to the rear compartment of a vehicle from the passenger compartment by allowing a secondary lock of the seatback. The Rear Seat Tether employs one or two tethers (one per folding seatback), each permanently connected to a T-handle anchor mounted in the rear compartment. To lock the folding seatback, the user can partially fold the seatback and attach the tether to another T-handle anchor mounted to the seatback. When the tether is affixed to both T-handle anchors, the seat cannot be folded down. To fold down the seatback, the tether must be removed from the anchor attached to the seatback. Important: Installation of the Trap Resistant Latch on some vehicles may require sheet metal and/or trim modifications to the rear compartment striker area. These modifications should be communicated with the customer prior to installations. Also, installation of the Trap Resistant Latch requires a rear compartment lid "ajar" switch. Prior to ordering the Trap Resistant Rear Compartment Kit, inspect the old deck lid latch to see if it is equipped with an "ajar" switch. If the vehicle is not equipped with this switch, P/N 12506174 must be ordered. After completing the Trap Resistant Rear Compartment Kit installation, provide the customer with the supplemental Owner's Manual insert included in the kit and demonstrate the system function. This program is specially structured for a single purchase price to the owner. The owner is responsible to pay a maximum of $50.00 U.S.; $80.00 Canadian for parts and labor to install the complete Trap Resistant Rear Compartment Kit and Rear Seat Tether(s), if required. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit Function/Installation > Page 6381 Parts are currently available from GMSPO. Labor Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 6386 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6391 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6392 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 6395 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6396 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6397 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6401 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6404 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6405 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6406 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6411 Brake Transaxle Shift Interlock (BTSI) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 6416 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Shift Lever To Transmission Nut ............................................................................................................................................................. 20 Nm (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Shifter A/T: Service and Repair 3T40 Automatic Transaxle Floor Shift Control Replacement (Floor Shift Control) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the automatic transmission range select lever cable from the selector lever. 3. Remove the range select lever cable from the cable bracket. 4. Remove the center console. 5. Remove the range select lever cable from the automatic transmission control. 6. Remove the cable grommet at the cowl. 7. Remove the cable from the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6422 INSTALLATION PROCEDURE 1. Install the cable to the vehicle through the cowl and the carpet. 2. Install the cable grommet in the cowl. 3. Install the range select lever cable at the automatic transmission control. 4. Install the center console. 5. Install the range select lever cable to the cable bracket. 6. Install the range select lever cable to the selector lever. 7. Connect the negative battery cable. 8. Adjust the cable. 8.1. Place the shift lever in N (Neutral). Rotate the selector shaft clockwise from P (Park) through R (Reverse) into N (Neutral). 8.2. Place the shift control assembly in N (Neutral). 8.3. Push the tab on the cable adjuster in order to adjust the cable in the cable mounting bracket. Floor Shift Control Replacement (Floor Shift) REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6423 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the automatic transmission control lever handle. 3. Remove the console. 4. Remove the range select lever cable from the automatic transmission control. 5. Remove the electrical connector. 6. Remove the automatic transmission control bolts. 7. Remove the automatic transmission control. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6424 1. Install the automatic transmission control. 2. Install the automatic transmission control bolts. 3. Install the electrical connector. 4. Install the range select lever cable to the automatic transmission control. 5. Install the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 6. Install the automatic transmission control lever handle. 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6425 Shifter A/T: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the automatic transmission control lever handle. 3. Remove the console. 4. Remove the range select lever cable from the automatic transmission control. 5. Remove the electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6426 6. Remove the automatic transmission control bolts. 7. Remove the automatic transmission control. INSTALLATION PROCEDURE 1. Install the automatic transmission control. 2. Install the automatic transmission control bolts. 3. Install the electrical connector. 4. Install the range select lever cable to the automatic transmission control. 5. Install the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 6. Install the automatic transmission control lever handle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6427 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Park Lock Cable Adjustment 1. Place the floor shift lever in the P (Park) position. 2. Turn the column lock cylinder to the Lock position. 3. Unseat the body housing lock from the body housing. Important: - No gap may exist between the metal terminal stop and the protruding end of the white plastic collar. If a gap does exist between the terminal stop and the collar, adjust the position of the park lock cable. - The white plastic collar must be flush or recessed about 1 mm (0.04 in) within the ignition park lock housing. If the white plastic collar is not in the proper location, adjust the position of the park lock cable. 4. Adjust the outer cable conduit in order to obtain the proper location for the white plastic housing in the ignition switch. Ensure that the body housing is still attached to the shift control mounting bracket. 5. Seat the body housing lock in the body housing while holding the outer cable conduit in position. 6. Inspect the park/lock control cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 6432 Shift Cable: Service and Repair Park Lock Cable Replacement Removal Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the console.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair 3. Remove the left sound insulator.See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Service and Repair 4. Remove the knee bolster. 5. Loosen the lower steering column bracket bolts. 6. Lower the steering column. 7. Place the transmission shift lever in the P (Park) position. Important: Do not proceed to the next step with the key in any other position. 8. Turn the ignition key to the RUN position. 9. Insert a screwdriver blade into the slot provided in the ignition switch inhibitor. 10. Depress the cable latch. Pull the control cable from the inhibitor. 11. Push the cable connector lock button at the shifter base to the up position. 12. Snap the cable from the park/lock lever pin. 13. Depress the two cable latches. Remove the control cable latches from the automatic transmission control. 14. Remove the control cable clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 6433 Installation Important: When installing a new park/lock cable, keep the shipping cover gauge attached until you are instructed to detach it. The shipping cover gauge will aid in the proper positioning of the cable. 1. Ensure that the cable lock button is in the up position. Place the shift lever in P (Park). 2. Snap the control cable connector into the automatic transmission control. 3. Place the ignition key in the RUN position. Important: Do not insert the cable with the key in any other position. 4. Snap the control cable into the inhibitor housing until the snap lock is seated. 5. Remove the shipping cover gauge. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 6434 6. Turn the key to the LOCK position. 7. Snap the control cable end onto the shift park/lock lever pin. 8. Push the cable connector hose forward in order to remove any slack. 9. With no load applied to the connector nose, snap the cable connector lock button down. Important: Test for proper operation of the park/lock control cable before installing the steering column to the instrument panel. 10. Raise and connect the steering column. 11. Tighten the lower steering column bracket bolts. 12. Install the knee bolster. 13. Install the left sound insulator. 14. Install the console. 15. Connect the negative battery cable. Inspection Important: No gap may exist between the metal terminal stop and the protruding end of the white plastic collar. If a gap does exist between the terminal stop and the collar, adjust the position of the park lock cable. - The white plastic collar must be flush or recessed about 1 mm (0.04 in) within the ignition park lock housing. If the white plastic collar is not in the proper location, adjust the position of the park lock cable. 1. Ensure that the terminal stop on the column end of the park/lock cable is touching the white collar that protrudes from the ignition switch. Complete the following steps in order to inspect: 1.1. Turn the column lock cylinder to the LOCK position. 1.2. Place the floor shift lever into the P (Park) position. 1.3. Verify the correct position of the terminal stop. 2. Ensure that the column lock cylinder remains in the Lock position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 6435 3. Ensure that the floor shift lever remains in the P (Park) position. 4. Gently depress the park/lock button on the floor shift lever until resistance is felt. 5. Verify that the white plastic collar travels no more than 1.5 mm (0.06 in). The floor shift lever must not come out of P (Park). 6. With the column lock cylinder On, verify proper movement of the floor shift lever through all of the gear selections. 7. While moving the floor shift lever through all of the drive gears, verify that the column lock cylinder cannot be turned to the Lock position. Important: Five inspections are used in order to verify proper installation. The installation must pass all 5 tests. If one or more of the tests fail, adjust the park/lock cable. Refer to Park Lock Cable Adjustment. . Ensure that the key can be removed with the column lock cylinder in the Lock position and the floor shift lever in the P (Park) position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6444 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6445 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6451 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6452 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Throttle Valve Assembly: Specifications 3T40 Automatic Transaxle TV Cable To Case ............................................................................................................................... .................................................... 9 Nm (75 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6457 Throttle Valve Assembly: Specifications 4T40-E Automatic Transaxle TV Cable To Case ............................................................................................................................... .................................................... 9 Nm (80 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > Page 6458 Throttle Valve Assembly: Adjustments 1. Depress and hold the readjustment tab. 2. Pull the cable conduit out until the slider mechanism hits the stop. 3. Release the button. 4. Remove the floor mat. 5. Firmly depress the accelerator pedal to the Wide Open Throttle (WOT) position. 6. Verify that the cable moves freely. The cable may appear to function properly with the engine stopped and cold. Recheck the engine after the engine is hot. 7. Road test the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > Page 6459 Throttle Valve Assembly: Service and Repair REMOVAL PROCEDURE IMPORTANT: Observe the TV cable routing when you remove the cable. Duplicate the cable routing when installing the cable. 1. Remove the TV cable end from the accelerator control lever assembly slot. 2. Remove the TV cable conduit end from the bracket by compressing the locking tangs. 3. Remove the TV cable routing clips or straps. 4. Remove the bolt that is securing the TV cable to the transmission. Pull up on the cable cover at the transmission until the cable is visible. 5. Remove the cable from the transmission link. 6. Remove the transmission case seal. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > Page 6460 1. Install a new seal into the transmission case hole. 2. Install the transmission end of the cable to the TV link. 3. Install the TV cable bolt and washer assembly to the transmission. ^ Tighten the bolts to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the TV cable routing clips or straps. 5. Install the TV cable conduit end to the bracket. 6. Install the TV cable into the accelerator control lever assembly slot. IMPORTANT: Do not damage or kink the wire cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Specifications > Page 6461 7. Pull on the upper end of the cable. The cable should travel a short distance with light resistance caused by the small return spring on the TV lever. When releasing the upper end of the TV cable, the cable should return to the zero TV position. 8. Adjust the TV cable. Refer to TV Cable Adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 6466 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6467 Torque Converter: Specifications Flywheel To Torque Converter ............................................................................................................ ..................................................... 62 Nm (46 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6468 Torque Converter: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement. 3. Remove the torque convertor assembly from the transmission. 4. Remove the torque convertor O-ring seal from the end of the turbine shaft. Use a screwdriver. INSTALLATION PROCEDURE 1. Install a new torque convertor 0-ring seal on the end of the turbine shaft. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6469 2. Install the torque convertor onto the transmission. 3. Install the transmission into the vehicle. Refer to Transmission Replacement. 4. Connect the negative battery cable. 5. Adjust the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6474 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Torque Converter Clutch: Initial Inspection and Diagnostic Overview In order to properly diagnose the Torque Converter Clutch (TCC) system, perform all electrical testing first and then the hydraulic testing. Refer to Powertrain Management and Automatic Transmission. For electrical schematics of the TCC system, refer to Powertrain Management. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6480 Torque Converter Clutch: Diagnostic Trouble Code Tests and Associated Procedures In order to properly diagnose the Torque Converter Clutch (TCC) system, perform all electrical testing first and then perform the hydraulic testing. The Torque Converter Clutch (TCC) is applied by fluid pressure, which is controlled by a solenoid valve. This solenoid valve is located inside of the automatic transmission assembly. The solenoid valve energizes or de-energizes by making or breaking an electrical circuit through the PCM and brake switch. FUNCTIONAL CHECK PROCEDURE 1. Install a tachometer or a scan tool. 2. Operate the vehicle until you have reached the proper operating temperature. 3. Drive the vehicle at 80-88 km/h (50-55 mph) with a light throttle (road load). 4. Maintaining throttle speed, lightly touch the brake pedal. Check for the release of the TCC and a slight increase in engine speed. 5. Release the brake and slowly accelerate. Check for a reapply of the converter clutch and a slight decrease in engine speed. PRELIMINARY CHECKING PROCEDURE IMPORTANT: ^ You may use a DLC scanner in order to verify the electrical circuit. Remember, a complete circuit does not indicate that the solenoid will apply. ^ Do not bench test using an automotive type battery. Accidentally crossed wires will damage the internal diodes of the TCC solenoid. The purpose of the preliminary checking procedure is to isolate external electrical problems from internal ones. EXTERNAL CONTROLS 1. Connect a voltmeter between the transmission electrical connector and the ground. 2. Turn the key ON. 3. If zero or low voltage is found, refer to Diagrams. 4. If 12 volts are present at the connector, refer to TCC hydraulic diagnosis. TORQUE CONVERTER STATOR The torque converter stator roller clutch can have two different malfunctions. ^ The stator assembly freewheels in both directions. ^ The stator assembly remains locked up at all times. POOR ACCELERATION AT LOW SPEED If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds above 50-55 km/h (30-35 mph), the car may act normally. For poor acceleration, you should first determine that the exhaust system is not blocked, the engine timing is correct, and the transmission is in First gear when starting out. If the engine freely accelerates to high RPM in Neutral, you can assume that the engine and the exhaust system are normal. Check for poor performance in Drive and Reverse to help determine if the stator is freewheeling at all times. POOR ACCELERATION AT HIGH SPEED If the stator is locked up at all times, performance is normal when accelerating from a standstill. Engine RPM and car speed are limited or restricted at high speeds. Visual examination of the converter may reveal a blue color from overheating. If the converter has been removed, you can check the stator roller clutch by inserting two fingers into the splined inner race of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the inner race clockwise, but you should have difficulty in moving the inner race counterclockwise or you may be unable to move the race at all. Do not use such items as the driven sprocket support or shafts in order to turn the race. The results may be misleading. NOISE IMPORTANT: Do not confuse this noise with pump whine noise, which is usually noticeable in PARK, NEUTRAL and all other gear ranges. Pump whine will vary with line pressure. You may notice a torque converter whine when the vehicle is stopped and the transmission is in DRIVE or REVERSE. This noise will increase as you increase the engine RPM. The noise will stop when the vehicle is moving or when you apply the torque converter clutch, because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually coming from the converter: 1. Place your foot on the brake. 2. Put the gear selector in DRIVE. NOTICE: You may damage the transmission if you depress the accelerator for more than six seconds. 3. Depress the accelerator to approximately 1,200 RPM for no more than six seconds. A torque converter noise will increase under this load. Replace the torque converter under any of the following conditions: ^ External leaks appear in the hub weld area. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6481 ^ The converter hub is scored or damaged. ^ The converter pilot is broken, damaged, or fits poorly into the crankshaft. ^ You discover steel particles after flushing the cooler and the cooler lines. ^ The pump is damaged, or you discover steel particles in the converter. ^ The vehicle has TCC shudder and/or no TCC apply. Replace the torque converter only after all hydraulic and electrical diagnoses have been made. The converter clutch material may be glazed. ^ The converter has an imbalance which cannot be corrected. Refer to Flexplate/Torque Converter Vibration Test, Flexplate/Torque Converter Vibration Test Procedure. ^ The converter is contaminated with engine coolant which contains antifreeze. ^ An internal failure occurs in the stator roller clutch. ^ You notice excessive end play. ^ Overheating produces heavy debris in the clutch. ^ You discover steel particles or clutch lining material in the fluid filter or on the magnet, when no internal parts in the unit are worn or damaged. This condition indicates that lining material came from the converter. Do not replace the torque converter if you discover any of the following symptoms: ^ The oil has an odor or the oil is discolored, even though metal or clutch facing particles are not present. ^ The threads in one or more of the converter bolt holds are damaged. Correct the condition with a thread insert. ^ Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in the unit and inside the fluid filter. The vehicle has been exposed to high mileage only. An exception may exist where the lining of the torque converter clutch dampener plate has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery, or police use. TCC SHUDDER The key to diagnosing Torque Converter Clutch (TCC) shudder is to note when it happens and under what conditions. TCC shudder which is caused by the transmission should only occur during the apply or the release of the converter clutch. Shudder should never occur after the TCC plate is fully applied. If the shudder occurs while the TCC is applying, the problem can be within the transmission or the torque converter. Something is causing one of the following conditions to occur: ^ Something is not allowing the clutch to become fully engaged. ^ Something is not allowing the clutch to release. ^ The clutch is releasing and applying at the same time. One of the following conditions may be causing the problem to occur: ^ Leaking turbine shaft seals ^ A restricted release orifice ^ A distorted clutch or housing surface due to long converter bolts ^ Defective friction material on the TCC plate If shudder occurs after the TCC has applied, most of the time there is nothing wrong with the transmission. As mentioned above, the TCC is not likely to slip after the TCC has been applied. Engine problems may go unnoticed under light throttle and load, but they become noticeable after the TCC apply when going up a hill or accelerating. This is due to the mechanical coupling between the engine and the transmission. Once TCC is applied, there is no torque converter (fluid coupling) assistance. Engine or driveline vibrations could be unnoticeable before TCC engagement. Inspect the following components in order to avoid misdiagnosis of TCC shudder. An inspection will also avoid the unnecessary disassembly of a transmission or the unnecessary replacement of a converter. ^ Spark plugs - Inspect for cracks, high resistance or a broken insulator. ^ Plug wires - Look in each end. If there is red dust (ozone) or a black substance (carbon) present, then the wires are bad. Also look for a white discoloration of the wire. This indicates arcing during hard acceleration. ^ Coils - Check for coil misfire. ^ Fuel injectors - The filter may be plugged. ^ Vacuum leak - The engine will not get a correct amount of fuel. The mixture may run rich or lean depending on where the leak occurs. ^ EGR valve - The valve may let in too much or too little unburnable exhaust gas and could cause the engine to run rich or lean. ^ MAP/MAF sensor - Like a vacuum leak, the engine will not get the correct amount of fuel for proper engine operation. ^ Carbon on the intake valves - Carbon restricts the proper flow of air/fuel mixture into the cylinders. ^ Flat cam - Valves do not open enough to let the proper fuel/air mixture into the cylinders. ^ Oxygen sensors - This sensor may command the engine too rich or too lean for too long. ^ Fuel pressure - This may be too low. ^ Engine mounts - Vibration of the mounts can be multiplied by TCC engagement. ^ Axle joints - Check for vibration. ^ TP Sensor - The TCC apply and release depends on the TP Sensor in many engines. If the TP Sensor is out of specification, TCC may remain applied during initial engine loading. ^ Cylinder balance - Bad piston rings or poorly sealing valves can cause low power in a cylinder. ^ Fuel contamination - This causes poor engine performance. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Valve To Valve Body ......................................................................................................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle > Page 6487 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6488 Torque Converter Clutch Solenoid: Service and Repair REMOVAL PROCEDURE 1. Remove the valve body cover. Refer to Valve Body Cover Replacement. 2. Remove the transmission mount bracket. 3. Disconnect the solenoid wire harness from the case electrical connector. 4. Disconnect the wire leads from the pressure switch. 5. Remove the torque converter clutch solenoid bolt from the control valve body. 6. Remove the 3rd clutch pressure switch. 7. Remove the 2nd clutch pressure switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6489 1. Install the 2nd clutch pressure switch, if applicable. ^ Tighten to 12 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install 3rd clutch pressure switch. ^ Tighten to 12 Nm (124 inch lbs.). 3. Install the torque converter clutch solenoid bolt to the control valve body. 4. Install the 0-ring. ^ Tighten to 12 Nm (124 inch lbs.). 5. Connect the wire leads to the pressure switch. 6. Connect the solenoid wire harness to the case electrical connector. 7. Install the transmission mount bracket. 8. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 9. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications Converter Shield .................................................................................................................................. ..................................................... 10 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6497 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6498 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6499 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6500 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6501 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6502 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6503 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 6504 Transmission Cooler: Specifications Cooler Connector ................................................................................................................................ ...................................................... 38 Nm (23 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Transmission Mount: Service and Repair 3T40 Automatic Transaxle A/T Mount Replacement (Front) REMOVAL PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Install the J 28467-360 to the transmission. Raise the transmission enough in order to unload the transmission mounts. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the left front wheel and tire assembly. Refer to Wheel Removal in Tires and Wheels. 5. Remove the left splash shield. 6. Remove the pipe expansion bolt from the transmission support assembly. 7. Remove the transmission mount to body bolts. 8. Lower the engine/transmission assembly just enough to be able to remove the transmission mount from the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6509 9. Remove the transmission mount. INSTALLATION PROCEDURE 1. Install the transmission mount to the transmission bracket. Do not tighten the bracket until the mount is fastened to the body. 2. Raise the engine and the transmission assembly. 3. Install the transmission mount to body bolts. ^ Tighten the bolts to 66 Nm (49 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the pipe expansion bolt to the transmission support assembly. ^ Tighten to bolt to 55 Nm (41 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6510 5. Install the left splash shield. 6. Install the left front tire and wheel assembly. Refer to Wheel Installation in Tires and Wheels. 7. Remove the engine support fixture. 8. Lower the vehicle. 9. Connect the negative battery cable. A/T Mount Replacement (Rear) REMOVAL PROCEDURE ^ Tools Required J 28467-360 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the air intake duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management. 3. Remove the TV cable, if equipped. Refer to TV Cable Replacement. 4. Remove the power brake booster line. 5. Remove the hose. 6. Install the J 28467-360. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Remove the engine mount strut. 9. Remove the left front tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 10. Remove the left splash shield. 11. Remove the crossmember. 12. Remove the left front ABS wheel speed sensor connector. 13. Remove the harness from the suspension support. 14. Remove the left front ball joint. Refer to Lower Ball Joint Replacement in Suspension. 15. Remove the left stabilizer bushing nuts. Refer to Stabilizer Shaft Replacement in Suspension. 16. Remove the stabilizer shaft from the left lower control arm. Refer to Stabilizer Shaft Replacement in Suspension. 17. Remove the left suspension support. Refer to Suspension Crossmember Replacement in Suspension. 18. Remove the left side drive axle from the transmission. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6511 19. Remove the transmission cooler pipes. Plug in order to prevent leakage. Refer to A/T Oil Cooler Pipes Replacement. 20. Remove the P/S lines from the P/S gear. Plug in order to prevent leakage. 21. Remove the transmission mount to body bolts. 22. Remove the pipe expansion bolt from the transmission support assembly. 23. Lower the engine and the transmission assembly just enough to be able to remove the transmission support assembly and the mount assembly. 24. Remove the transmission mount from the transmission support assembly. 25. Remove the transmission support assembly bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6512 26. Remove the transmission support assembly. INSTALLATION PROCEDURE. 1. Position the transmission support assembly into the vehicle. 2. Install the transmission support assembly bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the transmission mount to the transmission support assembly. 4. Raise the engine and the transmission assembly. 5. Install the transmission mount to body bolts. ^ Tighten the bolts to 66 Nm (49 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6513 6. Install the transmission pipe expansion bolt to the transmission support assembly. ^ Tighten the bolt to 55 Nm (41 ft. lbs.). 7. Install the P/S lines to the P/S gear. 8. Install the transmission cooler lines. Refer to A/T Oil Cooler Pipes Replacement. 9. Install the left drive axle to the transmission. Refer to Wheel Drive Shafts Replacement in Wheel Drive Shafts. 10. Install the left suspension support. Refer to Suspension Crossmember Replacement in Suspension. 11. Install the stabilizer shaft to the left lower control arm. Refer to Stabilizer Shaft Replacement in Suspension. 12. Install the left stabilizer bushing nuts. Refer to Stabilizer Shaft Replacement in Suspension. 13. Install the left front ball joint. Refer to Lower Ball Joint Replacement in Suspension. 14. Route and connect the left front ABS wheel speed sensor. 15. Install the crossmember. 16. Install the left splash shield. 17. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 18. Install the engine mount strut. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Install the power brake booster line. 22. Install the hose. 23. Install the TV cable, if equipped. Refer to TV Cable Replacement. 24. Install the air intake duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management. 25. Connect the negative battery cable. 26. Adjust the P/S oil level. Refer to Checking and Adding Power Steering Fluid in Power Steering System. 27. Adjust the TV cable. Refer to TV Cable Adjustment 28. Inspect the oil level. 29. Inspect the suspension alignment. Refer to Wheel Alignment Specifications in Wheel Alignment. 30. Inspect the transmission for oil leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6514 Transmission Mount: Service and Repair 4T40-E Automatic Transaxle A/T Mount Replacement (Front) REMOVAL PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Install the J 28467-360 to the transmission. 3. Remove the upper transmission mount assembly bolts. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the left front tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 6. Remove the left front splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6515 7. Remove the transmission mount expansion pipe bolt. 8. Remove the lower transmission mount assembly bolts. 9. Remove the transmission mount. INSTALLATION PROCEDURE 1. Install the transmission mount. 2. Install the lower transmission mount bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6516 ^ Tighten the bolts to 66 Nm (49 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the transmission mount expansion plug. 4. Install the left front splash shield. 5. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 6. Lower the vehicle. 7. Install the upper transmission mount bolts. ^ Tighten the bolts to 66 Nm (49 ft. lbs.). 8. Remove the engine support fixture. 9. Connect the negative battery cable. A/T Mount Replacement (Rear) REMOVAL PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6517 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Install the J 28467-360 to the transmission. 3. Remove the upper transmission support assembly bolts. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the left front tire and wheel assembly. Refer to Wheel Removal in Tires and Wheels. 6. Remove the left front splash shield. 7. Remove the transmission mount expansion pipe bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6518 8. Remove the lower transmission support assembly bolts. 9. Remove the transmission support. INSTALLATION PROCEDURE 1. Install the transmission support. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6519 2. Install the lower transmission support bolts. ^ Tighten the bolts to 130 Nm (96 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the transmission mount expansion plug. 4. Install the left front splash shield. 5. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 6. Lower the vehicle. 7. Install the upper transmission support assembly bolts. ^ Tighten the bolts to 130 Nm (96 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6520 8. Remove the engine support fixture. 9. Connect the negative battery cable. A/T Mount Replacement (Side) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the right front tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 4. Remove the right front splash shield. 5. Remove the transmission brace bolts. 6. Remove the transmission brace. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6521 1. Install the transmission brace. 2. Install the transmission brace to engine bolts. 3. Install the transmission brace to transmission bolts. ^ Tighten the bolts to 66 Nm (49 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the right front splash shield. 5. Install the right front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 6. Lower the vehicle. 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6530 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6531 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6537 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6538 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6539 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6540 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 6543 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6544 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6545 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6549 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6552 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6553 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6554 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: Customer Interest A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6563 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6564 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6565 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6566 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6567 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6568 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: All Technical Service Bulletins A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6578 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6579 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6580 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6581 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6582 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6583 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6589 Valve Body: Specifications Valve Body To Case ............................................................................................................................ ..................................................... 24 Nm (18 ft. lbs.) Valve Body To Case ........................................ ........................................................................................................................................... 11 Nm (8 ft. lbs.) Valve Body To Case Cover ..................................................................................................... .................................................................. 11 Nm (8 ft. lbs.) Valve Body To Case Cover ................... ..................................................................................................................................................... 11 Nm (8 ft. lbs.) Valve Body To Driven Sprocket Support ................................................................................................................................................. 24 Nm (18 ft. lbs.) Oil Pan And Valve Body Cover .......................................................................................... ....................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle Valve Body: Locations 3T40 (MD9) Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle > Page 6592 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle > Page 6593 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle > Page 6594 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle > Page 6595 Valve Body: Locations 4T40-E (MN4) Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > 3T40 (MD9) Automatic Transaxle > Page 6596 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement Valve Body: Service and Repair Valve Body Cover Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the transmission bracket. 3. Remove the control valve body cover bolts. 4. Remove the control valve body cover. 5. Remove the valve body cover gasket. 6. Determine if the washer is inverted on the bolts. IMPORTANT: Use Sealant compound GM P/N 12345282, or equivalent in order to reduce the potential for oil leaks on bolts. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6599 1. Install the valve body cover gasket. 2. Install the control valve body cover. 3. Install the control valve body cover bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the transmission mount bracket. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6600 Valve Body: Service and Repair Auxiliary Valve Body, Valve Body Pump Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the TV cable from the transmission. Refer to TV Cable Replacement. 3. Remove the transmission mount bracket. 4. Remove the valve body cover. Refer to Valve Body Cover Replacement. 5. Remove the bolt that secures the TCC solenoid to the valve body. 6. Remove the TCC solenoid. 7. Remove the TCC solenoid wiring connector from the case connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6601 8. Disconnect the TCC wires from the pressure switches. 9. Remove the TV lever bolts from the control valve body. 10. Remove the TV lever. 11. Remove the TV cable link. 12. Remove the remaining bolts that secure the valve body to the case cover. IMPORTANT: Do not lose the six check balls. Do not remove the green bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6602 13. Remove the valve body from the case cover. 14. Remove the green bolt. 15. Separate the valve body from the oil pump assembly. IMPORTANT: If any service is required on the valve body and/or oil pump, refer to the 3T40 Unit Repair. 16. Remove the check ball behind the control valve assembly. INSTALLATION PROCEDURE ^ Tools Required J 36850 TRANSJEL(R) 1. Install the check ball behind the oil pump assembly. 2. Install the control valve body to the oil pump assembly. 3. Install the check ball in the valve body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6603 4. Install the green bolt. If necessary, use or equivalent, in order to hold in place. NOTICE: Use TRANSJEL(R) J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Greases other than the recommended assembly lube will change the transmission fluid characteristics and will cause undesirable shift conditions or filter clogging. 5. Install the valve body to the case cover. 6. Install the valve body to case cover bolts. 7. Install the TV lever. 8. Install the TV cable link. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Cover Replacement > Page 6604 9. Install the TV lever bolts to the control valve body. 10. Connect the TCC wires and the wiring connectors. 11. Install the TCC solenoid. 12. Install the TCC solenoid bolt to the valve body. 13. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 14. Install the transmission mount bracket. 15. Install the TV cable to the transmission. Refer to TV Cable Replacement. 16. Connect the negative battery cable. 17. Adjust the TV cable. Refer to TV Cable Adjustment. 18. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the clutch actuator cylinder line. 3. Remove the clutch master cylinder assembly from the clutch actuator cylinder. 4. Remove the transmission. Refer to Transmission Replacement in Manual Transmission. 5. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 6609 6. Remove the clutch cover and the clutch disc. INSTALLATION PROCEDURE ^ Tools Required J 29074 Clutch Alignment Arbor 1. Align the Heavy Side of the flywheel assembly (stamped with an X), with the clutch cover Light Side (marked with paint). 2. Install the J 29074 in order to support the clutch cover to the flywheel assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 6610 3. Install the clutch cover to flywheel bolts. 3.1. Follow the tightening sequence. Tighten the bolts to 16 Nm (12 ft. lbs.). 3.2. Tighten the bolts to specifications. Refer to Fastener Tightening Specifications. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 5. Install the transmission. Refer to Transmission Replacement in Manual Transmission. 6. Install the clutch master cylinder assembly to the clutch actuator cylinder. 7. Connect the clutch actuator cylinder line. 8. Bleed the hydraulic system. Refer to Hydraulic Clutch Bleeding. 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Hydraulic Clutch Fluid (GM P/N 12345347 or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Page 6615 Clutch Fluid: Service and Repair NOTICE: Do not reuse the fluid that has been bled from a system in order to fill the clutch master cylinder reservoir for the following reasons: 1. The fluid may be aerated 2. The fluid may be contaminated 3. The fluid may contain too much moisture IMPORTANT: Maintain the fluid level in the clutch reservoir to the top step with GM P/N 12345347, or equivalent. 1. Clean dirt and grease from the cap in order to ensure that no foreign substances enter the system. 2. Attach a hose to the bleeder screw on the clutch actuator assembly. Submerge the other end of the hose in a container of Hydraulic Clutch Fluid GM P/N 12345347, or equivalent. 3. Depress the clutch pedal slowly and hold. 4. Loosen the bleeder screw to purge air. 5. ^ Tighten the bleeder screw to 2 Nm (18 inch lbs.) 6. Repeat steps 3 through 5 until air is purged. 7. Fill reservoir to the top step with GM P/N 12345347, or equivalent. 8. Repeat the bleeding procedure if there is a grinding noise during the clutch spin down procedure. Refer to Clutch Spin Down Time. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Clutch Master Cylinder and Clutch Pedal Bracket Nut ........................................................................................................................ 21 Nm (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6619 Clutch Master Cylinder: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the sound insulator from inside the vehicle. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 3. Remove the clutch master cylinder pushrod from the clutch pedal. 4. Remove the master cylinder retaining nuts at the front of the dash. 5. Remove the remote reservoir. 6. Disconnect the clutch actuator cylinder line. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6620 7. Remove the clutch master cylinder assembly from the clutch actuator cylinder. INSTALLATION PROCEDURE 1. Install the clutch master cylinder assembly to the clutch actuator cylinder. 2. Connect the clutch actuator cylinder line. 3. Install the remote reservoir. 4. Install the master cylinder retaining nuts at the front of the dash. ^ Tighten the nuts evenly to 21 Nm (15 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 6621 NOTICE: Refer to Fastener Notice in Service Precautions. 5. Install the pushrod to the clutch pedal. 6. Adjust the cruise control clutch switch, if equipped. Refer to Cruise Control Cable Adjustment (LN2) or Cruise Control Cable Adjustment (LD9) in Cruise Control. 7. Install the sound insulator. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 8. Bleed the hydraulic system. Refer to Hydraulic Clutch Bleeding. 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch Actuator Bleed Screw .............................................................................................................................................................. 2 Nm (18 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 6625 Clutch Slave Cylinder: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the clutch actuator cylinder line. 3. Remove the transmission. Refer to Transmission Replacement. 4. Remove the clutch actuator cylinder from the transmission. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 6626 1. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 2. Install the clutch actuator cylinder to the transmission. 3. Install the transmission. Refer to Transmission Replacement. 4. Connect the clutch actuator cylinder line. 5. Bleed the hydraulic system. Refer to Hydraulic Clutch Bleeding. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch Master Cylinder and Clutch Pedal Bracket Nut ........................................................................................................................ 21 Nm (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 6630 Clutch Pedal Assembly: Service and Repair REMOVAL PROCEDURE IMPORTANT: Service the clutch pedal and bracket as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the sound insulator from inside the vehicle. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 3. Remove the clutch master cylinder pushrod from the clutch pedal. 4. Remove the clutch pedal and bracket mounting nuts. 5. Remove the clutch pedal and bracket assembly. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 6631 1. Install the clutch pedal and bracket assembly. 2. Install the clutch pedal and bracket mounting nuts. ^ Start with the lower nuts, tighten the nuts to 23 Nm (17 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the clutch master cylinder pushrod bushing on the pedal. Lubricate the bushing. 4. Install the clutch master cylinder pushrod to the clutch pedal. 5. Adjust the cruise control clutch switch, if equipped. Refer to Cruise Control Cable Adjustment (LN2) or Cruise Control Cable Adjustment (LD9) in Cruise Control. 6. Install the sound insulator. Refer to Insulator Replacement - IP in Instrument Panel, Gauges and Warning Indicators. 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 6635 Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Cover to Flywheel Bolt ............................................................................................................. .............................................................................................. 16 Nm (12 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6639 Pressure Plate: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the clutch actuator cylinder line. 3. Remove the clutch master cylinder assembly from the clutch actuator cylinder. 4. Remove the transmission. Refer to Transmission Replacement in Manual Transmission. 5. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6640 6. Remove the clutch cover and the clutch disc. INSTALLATION PROCEDURE ^ Tools Required J 29074 Clutch Alignment Arbor 1. Align the Heavy Side of the flywheel assembly (stamped with an X), with the clutch cover Light Side (marked with paint). 2. Install the J 29074 in order to support the clutch cover to the flywheel assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6641 3. Install the clutch cover to flywheel bolts. 3.1. Follow the tightening sequence. Tighten the bolts to 16 Nm (12 ft. lbs.). 3.2. Tighten the bolts to specifications. Refer to Fastener Tightening Specifications. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 5. Install the transmission. Refer to Transmission Replacement in Manual Transmission. 6. Install the clutch master cylinder assembly to the clutch actuator cylinder. 7. Connect the clutch actuator cylinder line. 8. Bleed the hydraulic system. Refer to Hydraulic Clutch Bleeding. 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) DISASSEMBLY PROCEDURE ^ Tools Required J 8039-A Snap Ring Pliers IMPORTANT: Do not cut through boot and damage sealing surface of outer housing (1). 1. Remove the small retaining clamp from the halfshaft bar (4) with a side cutter. Discard the small retaining clamp. 2. Remove the larger boot retaining clamp from the inboard joint with a side cutter. Discard the boot retaining clamp. 3. Separate the housing assembly (1) from the boot at large diameter. 4. Slide boot away from joint along halfshaft bar. 5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure: 6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A. IMPORTANT: Never reuse the spacer ring (2). 7. Place a brass drift on the area of the tripot spider (1) next to the halfshaft bar (3). 8. Tap on the brass drift with the hammer. 9. Remove the tripot spider assembly (1) from the halfshaft bar (3). IMPORTANT: Handle the tripot spider assembly (1) with care. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6653 10. Remove the spacer ring (1) from the shoulder of the halfshaft bar using J 8039-A. 11. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates. ^ The tripot balls ^ The needle rollers ^ The housing 12. Dry all the parts. 13. Remove the boot from the halfshaft bar. 14. Inspect the following parts for damage or wear: ^ The joint boot ^ The spider (3) ^ The housing ^ The tripot balls ^ The needle rollers ^ The retaining ring (1) ASSEMBLY PROCEDURE ^ Tools Required J 35910 Seal Clamp Tool 1. Install the new small boot retaining clamp on the neck of the boot. 2. Do not crimp the small boot retaining clamp. 3. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 4. Slide the tripot boot onto the halfshaft bar, passing the boot grooves of the halfshaft bar toward the CV end of the halfshaft bar. 5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar. IMPORTANT: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3). 6. Place the tripot spider assembly (3) onto the halfshaft bar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6654 7. Place the halfshaft assembly onto the arbor press. ^ The tripot spider assembly must be on the press plate. ^ The CV joint assembly must be under the press head. 8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs. press load during assembly. 9. Remove the halfshaft assembly from the arbor press. 10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar. 11. Slide the tripot boot (7) the corresponding groove on the halfshaft bar. 12. Crimp the small boot retaining clamp (6) using J 35910. 13. Place approximately a 1/4 of the grease from the service kit in boot. Use the remainder to repack the housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6655 14. Slide the housing (1) over the spider assembly on the shaft (2). Engage the tripot boot. 15. Position the large boot retaining clamp around the tripot boot (3). IMPORTANT: The end of the tripot boot (3) must be next to the boot stop on the housing (1). 16. Position joint assembly at the proper vehicle dimension. IMPORTANT: The boot (2) must not be dimpled, stretched or out of shape in any way. If the boot (2) is not shaped correctly, carefully equalize pressure by disassembling and reassembling the housing (4) into the large boot opening at proper vehicle dimension. IMPORTANT: Align the following items while latching: ^ The boot ^ The housing (1) ^ The large boot retaining clamp (2) 17. Crimp the large boot retaining clamp (2) with J 35910. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6656 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint & Boot Replacement (Free 2.4L) DISASSEMBLY PROCEDURE - J 8059 Snap Ring Pliers - J 38868 Stub Shaft Removal Tool - J 6125-1B Impact Slide Hammer IMPORTANT: The transaxle stub shaft may disengage from the transaxle during halfshaft tripot removal. If this condition occurs, transaxle fluid may leak from the transaxle through the stub shaft location. 1. Perform the following steps if the transaxle stub shaft has disengaged into the female tripot housing on removal from transaxle. 2. Remove the snap ring from the stub shaft. IMPORTANT: Never reuse the snap ring. 3. Discard the snap ring. 4. Connect the J 38868 to the snap ring groove on the stub shaft and connect an J 6125-1A to the J 38868. 5. Use the J 6125-1A to remove the shaft from the tripot housing. 6. Install new snap rings onto the stub shaft. 7. Refer to the transaxle unit repair for the proper installation of the stub shaft into the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6657 8. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. IMPORTANT: Do not cut through the halfshaft inboard boot and damage sealing surface of the outer housing and the trilobal tripot bushing. 9. Discard the small boot retaining clamp. 10. Remove the large boot retaining clamp from the tripot joint with side cutter. 11. Discard the large boot retaining clamp. 12. Separate the tripot boot from the trilobal tripot bushing at the large diameter. 13. Slide the boot away from the joint along the halfshaft bar. 14. Remove the housing from the tripot joint spider and the halfshaft bar. 15. Spread spacer ring (2) with J 8059. 16. Slide the spacer ring (2) and tripot joint spider back on halfshaft bar (1). 17. Remove the halfshaft bar retaining ring from the groove on the halfshaft bar (1). 18. Slide tripot joint spider assembly off of the halfshaft bar (1). 19. Clean the following items with cleaning solvent: ^ The tripot balls ^ The needle rollers ^ The housing 20. Remove all traces of old grease and any contaminates. Dry all the parts. 21. Remove the trilobal tripot bushing from the housing. 22. Remove the spacer ring (2) and the boot (3) from the halfshaft bar. 23. Inspect the following parts for damage or wear: ^ The halfshaft inboard boot (3) ^ The tripot joint spider assembly (1) ^ The housing ^ The trilobal tripot bushing ^ The tripot balls ^ The needle rollers ASSEMBLY PROCEDURE ^ Tools Required J 8059 Snap Ring Pliers - J 35566 Earless Seal Clamp Tool - J 35910 Seal Clamp Tool Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6658 1. Install the new small boot retaining clamp (2) on the neck of the tripot boot (1). 2. Do not crimp the small boot retaining clamp. 3. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 4. Slide the tripot boot (7) onto the halfshaft bar. 5. Position the neck of the tripot boot in the boot groove (3) on the halfshaft bar. Crimp the boot retaining clamp (6). ^ Crimp the boot retaining clamp using J 35910 to 136 Nm (100 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Install the spacer ring (2) on the halfshaft bar (1) and beyond the second groove. 7. Slide the tripot joint spider assembly (3) toward the spacer ring as far as it will go on the halfshaft bar. IMPORTANT: Ensure that the counterbored face of the tripot joint spider (4) faces end of the halfshaft bar. 8. Install the halfshaft bar retaining ring (2) in the groove of the halfshaft bar using J 8059. 9. Slide the tripot joint spider assembly (3) towards the end of the halfshaft bar. 10. Reseat the spacer ring in the groove on the halfshaft bar. 11. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use the remainder of the grease to repack the housing. Ensure the bushing is flush with the face of the housing. 12. Install the trilobal tripot bushing to housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6659 13. Position the larger new clamp (3) on the halfshaft inboard boot (2). 14. Slide the housing (4) over the tripot joint spider assembly on the halfshaft bar (1). 15. Slide the large diameter of the halfshaft inboard boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing. 16. Locate the lip of the boot in the groove. 17. Position the joint assembly at the proper vehicle dimension. IMPORTANT: Align the following items while latching: ^ The halfshaft inboard boot (3) ^ The housing (1) ^ The large clamp (2) IMPORTANT: The halfshaft inboard boot (3) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard boot (3) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard boot (3) properly by hand. Remove the thin, flat, blunt tool. 18. Latch the boot retaining clamp (2) using J 35566. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6660 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint & Boot Replacement (Tripot 2.2L) DISASSEMBLY PROCEDURE ^ Tools Required J 41398 CV Puller - J 2619-01 Slide Hammer Assembly IMPORTANT: Due to the helical splines on the halfshaft bar, disassembly and assembly of the joints will be difficult. Follow the instructions provided. 1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the large boot retaining clamp. 2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter and discard. 3. Separate the CV joint boot from the CV joint race (2) at the large diameter. 4. Slide the boot away from the joint along the halfshaft bar. 5. Wipe the grease from the face of the CV joint inner race (1). 6. Before removing the CV joint assembly from the halfshaft bar, perform the following procedure: 6.1. Choose a reference mark (B) on the halfshaft bar. 6.2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement. The measurement is (A). 7. Clamp the halfshaft (1) into a vise. 8. Attach the J 41398 to the threaded area of the outer race (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6661 9. Attach J 2619-01 onto the outer end of the J 41398. 10. Use the J 2619-01 to remove the CV joint from the halfshaft bar. 11. Remove J 2619-01 and J 41398 from the CV joint. 12. Remove the retaining ring from the halfshaft bar. Discard the retaining ring. IMPORTANT: Never reuse the retaining ring. 13. Remove the CV joint boot (1) from the halfshaft bar. 14. Place a brass drift against the CV joint cage (1). 15. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 18. Repeat this process to remove all six of the balls. 19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2). 20. Lift out the cage (4) and the inner race. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6662 21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 23. Dry all the parts. 24. Check the CV joint assembly for unusual wear, cracks, or other damage. 25. Replace any damaged parts. 26. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). ASSEMBLY PROCEDURE ^ Tools Required J 35910 Seal Clamp Tool 1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race. 2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2). 3. Insert the inner race into the cage. 4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6663 IMPORTANT: Ensure that the retaining ring side of the inner race faces the outer race. 5. Install the cage and the inner race into outer race. 6. Place a brass drift against the CV joint cage (1). 7. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 9. Repeat this process to install all six of the balls. 10. Pack the CV joint with half of the grease supplied in the service kit. 11. Install the new small retaining clamp on the neck of the boot. Do not crimp. 12. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 13. Slide the CV joint boot onto the halfshaft bar. Expose the reference mark (B) by sliding the CV joint boot up the halfshaft bar toward the tripot end. 14. Position the large boot retaining clamp around the joint boot. 15. Place the new retaining ring onto the halfshaft bar. 16. While supporting the tripot assembly, place the halfshaft assembly onto the arbor press with the CV assembly under the press head. 17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 4,000 lbs. press load during assembly. 18. Remove the halfshaft assembly from the arbor press. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6664 19. Measure the distance between the reference mark on the halfshaft bar (B) and the face of the CV joint inner race (1). 20. Compare the mark with the measurement made before disassembly. The distance measured after assembly must be within +-1 mm of the distance measured before disassembly. 21. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly. 22. Place the neck of the CV joint boot into the boot groove on the halfshaft bar. IMPORTANT: Check the clamp position during the crimping operation in order to ensure the clamp (1) is positioned correctly around the entire circumference. 23. Crimp the small retaining clamp (1) by using J 35910. 24. Place the remaining grease from the service kit inside the boot. 25. Measure approximately 17.5 mm up from the bottom edge of the CV outer joint assembly. 26. Slide the large diameter of the boot with the large boot retaining clamp in place over the outside of CV joint. IMPORTANT: The CV joint boot must not be dimpled, stretched or out of shape in any way. If boot is not shaped correctly, equalize pressure in the boot and shape the boot properly by hand. 27. Locate the boot lip to the ridge of the CV outer joint assembly as measured in the previous step. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement (Tripot 2.2L) > Page 6665 28. Crimp boot retaining clamp (1). ^ Crimp boot retaining clamp with J 35910 176 Nm (130 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint DISASSEMBLY PROCEDURE ^ Tools Required J 8039-A Snap Ring Pliers IMPORTANT: Do not cut through boot and damage sealing surface of outer housing (1). 1. Remove the small retaining clamp from the halfshaft bar (4) with a side cutter. Discard the small retaining clamp. 2. Remove the larger boot retaining clamp from the inboard joint with a side cutter. Discard the boot retaining clamp. 3. Separate the housing assembly (1) from the boot at large diameter. 4. Slide boot away from joint along halfshaft bar. 5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure: 6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A. IMPORTANT: Never reuse the spacer ring (2). 7. Place a brass drift on the area of the tripot spider (1) next to the halfshaft bar (3). 8. Tap on the brass drift with the hammer. 9. Remove the tripot spider assembly (1) from the halfshaft bar (3). IMPORTANT: Handle the tripot spider assembly (1) with care. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6670 10. Remove the spacer ring (1) from the shoulder of the halfshaft bar using J 8039-A. 11. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates. ^ The tripot balls ^ The needle rollers ^ The housing 12. Dry all the parts. 13. Remove the boot from the halfshaft bar. 14. Inspect the following parts for damage or wear: ^ The joint boot ^ The spider (3) ^ The housing ^ The tripot balls ^ The needle rollers ^ The retaining ring (1) ASSEMBLY PROCEDURE ^ Tools Required J 35910 Seal Clamp Tool 1. Install the new small boot retaining clamp on the neck of the boot. 2. Do not crimp the small boot retaining clamp. 3. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 4. Slide the tripot boot onto the halfshaft bar, passing the boot grooves of the halfshaft bar toward the CV end of the halfshaft bar. 5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar. IMPORTANT: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3). 6. Place the tripot spider assembly (3) onto the halfshaft bar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6671 7. Place the halfshaft assembly onto the arbor press. ^ The tripot spider assembly must be on the press plate. ^ The CV joint assembly must be under the press head. 8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs. press load during assembly. 9. Remove the halfshaft assembly from the arbor press. 10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar. 11. Slide the tripot boot (7) the corresponding groove on the halfshaft bar. 12. Crimp the small boot retaining clamp (6) using J 35910. 13. Place approximately a 1/4 of the grease from the service kit in boot. Use the remainder to repack the housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6672 14. Slide the housing (1) over the spider assembly on the shaft (2). Engage the tripot boot. 15. Position the large boot retaining clamp around the tripot boot (3). IMPORTANT: The end of the tripot boot (3) must be next to the boot stop on the housing (1). 16. Position joint assembly at the proper vehicle dimension. IMPORTANT: The boot (2) must not be dimpled, stretched or out of shape in any way. If the boot (2) is not shaped correctly, carefully equalize pressure by disassembling and reassembling the housing (4) into the large boot opening at proper vehicle dimension. IMPORTANT: Align the following items while latching: ^ The boot ^ The housing (1) ^ The large boot retaining clamp (2) 17. Crimp the large boot retaining clamp (2) with J 35910. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6673 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint & Boot Replacement-Tripot Joint DISASSEMBLY PROCEDURE ^ Tools Required J 41398 CV Puller - J 2619-01 Slide Hammer Assembly IMPORTANT: Due to the helical splines on the halfshaft bar, disassembly and assembly of the joints will be difficult. Follow the instructions provided. 1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the large boot retaining clamp. 2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter and discard. 3. Separate the CV joint boot from the CV joint race (2) at the large diameter. 4. Slide the boot away from the joint along the halfshaft bar. 5. Wipe the grease from the face of the CV joint inner race (1). 6. Before removing the CV joint assembly from the halfshaft bar, perform the following procedure: 6.1. Choose a reference mark (B) on the halfshaft bar. 6.2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement. The measurement is (A). 7. Clamp the halfshaft (1) into a vise. 8. Attach the J 41398 to the threaded area of the outer race (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6674 9. Attach J 2619-01 onto the outer end of the J 41398. 10. Use the J 2619-01 to remove the CV joint from the halfshaft bar. 11. Remove J 2619-01 and J 41398 from the CV joint. 12. Remove the retaining ring from the halfshaft bar. Discard the retaining ring. IMPORTANT: Never reuse the retaining ring. 13. Remove the CV joint boot (1) from the halfshaft bar. 14. Place a brass drift against the CV joint cage (1). 15. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 18. Repeat this process to remove all six of the balls. 19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2). 20. Lift out the cage (4) and the inner race. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6675 21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 23. Dry all the parts. 24. Check the CV joint assembly for unusual wear, cracks, or other damage. 25. Replace any damaged parts. 26. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). ASSEMBLY PROCEDURE ^ Tools Required J 35910 Seal Clamp Tool 1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race. 2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2). 3. Insert the inner race into the cage. 4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6676 IMPORTANT: Ensure that the retaining ring side of the inner race faces the outer race. 5. Install the cage and the inner race into outer race. 6. Place a brass drift against the CV joint cage (1). 7. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 9. Repeat this process to install all six of the balls. 10. Pack the CV joint with half of the grease supplied in the service kit. 11. Install the new small retaining clamp on the neck of the boot. Do not crimp. 12. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). 13. Slide the CV joint boot onto the halfshaft bar. Expose the reference mark (B) by sliding the CV joint boot up the halfshaft bar toward the tripot end. 14. Position the large boot retaining clamp around the joint boot. 15. Place the new retaining ring onto the halfshaft bar. 16. While supporting the tripot assembly, place the halfshaft assembly onto the arbor press with the CV assembly under the press head. 17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 4,000 lbs. press load during assembly. 18. Remove the halfshaft assembly from the arbor press. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6677 19. Measure the distance between the reference mark on the halfshaft bar (B) and the face of the CV joint inner race (1). 20. Compare the mark with the measurement made before disassembly. The distance measured after assembly must be within +-1 mm of the distance measured before disassembly. 21. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly. 22. Place the neck of the CV joint boot into the boot groove on the halfshaft bar. IMPORTANT: Check the clamp position during the crimping operation in order to ensure the clamp (1) is positioned correctly around the entire circumference. 23. Crimp the small retaining clamp (1) by using J 35910. 24. Place the remaining grease from the service kit inside the boot. 25. Measure approximately 17.5 mm up from the bottom edge of the CV outer joint assembly. 26. Slide the large diameter of the boot with the large boot retaining clamp in place over the outside of CV joint. IMPORTANT: The CV joint boot must not be dimpled, stretched or out of shape in any way. If boot is not shaped correctly, equalize pressure in the boot and shape the boot properly by hand. 27. Locate the boot lip to the ridge of the CV outer joint assembly as measured in the previous step. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint & Boot Replacement-Tripot Joint > Page 6678 28. Crimp boot retaining clamp (1). ^ Crimp boot retaining clamp with J 35910 176 Nm (130 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT WHEEL BEARINGS AND/OR HUB REMOVAL PROCEDURE ^ Tools Required: J 28733-B Front Hub Spindle Remover 1. Remove the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in Drive Axles, Bearings and Joints. 2. Remove brake caliper bolts and support caliper. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 3. Remove the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Remove the bolts (1) from the hub and bearing assembly (3). 5. Remove the hub and bearing assembly (1) from the steering knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6684 1. Install the hub and bearing assembly (1) into the steering knuckle (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the hub and bearing bolts (1) and washers (2). Tighten Tighten the bolts to 95 Nm (70 ft. lbs.). 3. Install the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Install the brake caliper and bolts. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 5. Install the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in DRIVE AXLES, BEARINGS AND JOINTS. 6. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 6685 Wheel Bearing: Service and Repair Rear REAR HUB AND/OR BEARINGS REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the brake drum. Refer To BRAKE DRUM REPLACEMENT. 4. Remove the hub and bearing assembly (4) from the axle (2). The top rear attaching bolt (5) and nut (1) will not clear the brake shoe (3) when removing the hub and bearing assembly. Partially remove the hub and bearing assembly prior to removing this bolt. 5. Disconnect the rear ABS wheel speed sensor wire connector. INSTALLATION PROCEDURE 1. Connect the rear ABS wheel speed sensor wire connector. 2. Install the hub and bearing assembly (4). Position the top rear attaching bolt (5) in the hub and bearing assembly prior to the installation in the axle assembly (2). Tighten Tighten the hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 4. Install the tire and wheel assemblies. Refer to WHEEL REMOVAL. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Drive Axle Nut 200 Nm (144 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 6691 Axle Nut: Specifications Rear Hub and Bearing to Axle Bolts 60 Nm (44 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Tighten the flywheel bolts to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6695 Flex Plate: Service and Repair REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission converter cover bolts. 3. Remove the transmission converter cover. 4. Mark the relationship of the converter to the flywheel. 5. Remove the 3 bolts that attach the converter to the flywheel. INSTALLATION PROCEDURE 1. Install the bolts that attach the converter to the flywheel. ^ Tighten the bolts to 62 Nm (46 ft. lbs.). Re-torque the first bolts after all 3 bolts have been tightened. NOTICE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6696 2. Install the converter cover. 3. Install the converter cover bolts. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Engine Flywheel Bolts ......................................................................................................................... ........................................................ 75 Nm (55 ft.lb) Clutch Cover to Flywheel Bolt ........................................................................................................................................................... 20 Nm (15 ft.lb) + 30° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transaxle ................................................................................................................................ ............................................... 1.9 Liters (2.0 Quarts) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6705 Fluid - M/T: Fluid Type Specifications DEXRON Synchromesh Transmission Fluid (GM P/N 12345349 or equivalent). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 6706 Fluid - M/T: Testing and Inspection INSPECTION PROCEDURE IMPORTANT: ^ Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. ^ The fluid level indicator must be fully seated during vehicle operation or leakage will occur at the vent plug. 1. Remove the fluid level indicator. 2. Read the fluid level indicator. 3. If the indicator reads ADD or below, fill the transaxle to FULL with synchromesh transaxle fluid GM P/N 12345349 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 6707 Fluid - M/T: Service and Repair INSPECTION PROCEDURE IMPORTANT: ^ Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. ^ The fluid level indicator must be fully seated during vehicle operation or leakage will occur at the vent plug. 1. Remove the fluid level indicator. 2. Read the fluid level indicator. 3. If the indicator reads ADD or below, fill the transaxle to FULL with synchromesh transaxle fluid GM P/N 12345349 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. Refer to Battery Disconnect Caution in Service Precautions. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Support the vehicle with a safety stand. 4. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and Wheels. 5. Remove the stabilizer shaft from the shift control arm. 6. Remove the ball joint from the steering knuckle. Refer to Lower Ball Joint Replacement in Front Suspension. 7. Remove the drive axle from: ^ The left oil seal - the transaxle ^ The right oil seal - the intermediate shaft 8. Remove the intermediate shaft. 9. Remove the drive axle oil seal. 10. Fill between the oil seal lips with chassis grease GM P/N 1051344 or equivalent. INSTALLATION PROCEDURE ^ Tools Required J 26936 Seal Installer - J 8092 Drive Handle 1. Install the drive axle oil seal with J 26936 and J 8092. 2. Install the intermediate shaft. 3. Install the drive axle. 4. Install the ball joint. Refer to Lower Ball Joint Replacement in Suspension. 5. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Suspension. 6. Install the tire and wheel assembly. 7. Remove the safety stand. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Page 6711 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control (Actuator) Shifter M/T: Service and Repair Shift Control (Actuator) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the shift cables. 3. Remove the shift control box bolts. 4. Remove the shift control box. 5. Disassemble the shift control box. 6. Assemble the shift control box using the following procedure: 6.1. Assemble the stopper cam and the internal lever. 6.2. Install the stopper cam and internal lever to the shift lever assembly. IMPORTANT: Align the serrations on the stopper cam and internal lever. 7. Inspect the alignment of the stopper cam with the center on the internal lever. 8. Reverse the inhibitor mechanism for proper operation. 9. Install the new roll pin to the internal lever. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control (Actuator) > Page 6716 1. Install the shift control box. 2. Install the shift control box bolts. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the shift cables. 4. Inspect for proper shifting. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control (Actuator) > Page 6717 Shifter M/T: Service and Repair Shift Control (Shifter) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the following parts from the shift control: 2.1. The knob 2.2. The boot 2.3. The front console 3. Remove the shift cables from the pin on the shift control. 4. Remove the spring clip holding the cables to the shift control. 5. Remove the shift control. INSTALLATION PROCEDURE 1. Install the shift control. 2. Install the shift control nuts. ^ Tighten the nuts to 25 Nm (18 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the shift cables to the pin on the shift control. 4. Install the spring clip that holds the cables to the shift control. 5. Install the following parts on the shift control assembly: 5.1. The front console 5.2. The boot 5.3. The knob Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control (Actuator) > Page 6718 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair Shift Cable: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Fastener Notice in Service Precautions. 2. Remove the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 3. Disconnect the cable ends from the shifter. 4. Remove the forward cable from the anchor. 5. Remove the reverse cable from the anchor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 6723 6. On the transmission end, disconnect the forward cable end from the shift actuator. 7. Disconnect the reverse cable from the shift actuator. 8. Remove both cables from the underhood cable bracket. 9. Position aside the passenger front carpet. Refer to Carpet Replacement - Front in Interior Trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 6724 10. Remove the rear floor duct elbow. 11. Separate the grommet from the floor plan. 12. Pull the cables through the passenger floor opening. INSTALLATION PROCEDURE 1. Feed the cable assembly through the passenger floor pan opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 6725 2. Install the grommet flush with the floor opening. 3. Install the rear floor right side elbow duct. 4. Position and install the passenger side carpet. 5. Install the cables into the underhood bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 6726 6. Connect the reverse cable to the shift actuator. 7. Connect the forward cable to the sift actuator. 8. Install the reverse cable to the anchor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 6727 9. Install the forward cable to the anchor. 10. Connect the cables to the shifter. 11. Install the console. Refer to Console Replacement (Chevrolet) or Console Replacement (Pontiac) in Instrument Panel, Gauges and Warning Indicators. 12. Connect the battery. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Front (lower) transaxle mount bolts ..................................................................................................... ...................................................................................... 60 Nm (44 ft. lbs.) Rear (upper) transaxle mount bolts ..................................................................................................... ...................................................................................... 75 Nm (55 ft. lbs.) Rear transmission mount thru bolt ...................................................................................................................................................... 120 Nm (89 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle Mount Replacement Transmission Mount: Service and Repair Transaxle Mount Replacement INSPECTION PROCEDURE 1. Pull up and down on the transaxle case while observing the front lower transaxle mount. 2. Replace a mount when the following conditions occur: 3. The rubber separates from the metal case 4. If movement occurs between the metal plate of the mount and its attaching point, tighten the mount bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. REMOVAL PROCEDURE ^ Tools Required J 28467-360 Engine Support Fixture Adapter. 1. Disconnect the negative battery cable. Install J 28467-360. Raise the transaxle enough to take pressure off of the motor mounts. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the left front tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 3. Remove the left front splash shield. 4. Remove the front transaxle mount bolts. 5. Remove the front transaxle mount. 6. Remove the rear transaxle mount bolts. 7. Remove the rear transaxle mount. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle Mount Replacement > Page 6733 1. Install the front transaxle mount. 2. Install the front transaxle mount bolts. ^ Tighten the bolts to 60 Nm (44 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the rear transaxle mount. 4. Install the rear transaxle mount bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). 5. Install the left front splash shield. 6. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 7. Remove J 28467-360. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle Mount Replacement > Page 6734 Transmission Mount: Service and Repair Transmission Mount Replacement-Front INSPECTION PROCEDURE 1. Pull up and down on the transaxle case while observing the front lower transaxle mount. 2. Replace a mount when the following conditions occur: 3. The rubber separates from the metal case 4. If movement occurs between the metal plate of the mount and its attaching point, tighten the mount bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. REMOVAL PROCEDURE 1. Disconnect the negative battery cable. use a screw jack in order to raise the transaxle enough to take pressure off of the motor mounts. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the left front tire and the wheel assembly. Refer to Wheel Removal in Tires and Wheels. 3. Remove the left front splash shield. Refer to Splash Shield Replacement - Wheelhouse in Body Front End. 4. Remove the front transaxle mount bolts. 5. Remove the front transaxle mount. INSTALLATION PROCEDURE 1. Install the front transaxle mount. 2. Install the front transaxle mount bolts. ^ Tighten the bolts to 60 Nm (44 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the left front splash shield. Refer to Splash Shield Replacement - Wheelhouse in Body Front End. 4. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and Wheels. 5. Remove J 28467-360. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transaxle Mount Replacement > Page 6735 Transmission Mount: Service and Repair Transmission Mount Replacement-Rear REMOVAL PROCEDURE 1. Remove the front suspension support. Refer to Suspension Crossmember Replacement in Suspension. 2. Remove the rear transmission mount thru bolt. 3. Remove the mount bolt. INSTALLATION PROCEDURE 1. Position and install the mount. 2. Install the thru bolt. ^ Tighten the thru bolt to 120 Nm (89 ft. lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the suspension support. Refer to Suspension Crossmember Replacement in Suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6742 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 6743 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6752 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6753 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6759 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6760 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 01-06-01-030A > May > 02 > Engine Excessive Oil Consumption Valve Cover: All Technical Service Bulletins Engine - Excessive Oil Consumption File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-01-030A Date: May, 2002 TECHNICAL Subject: Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover) Models: 1998-2001 Chevrolet Cavalier 1998-2001 Pontiac Sunfire 1998-2001 Chevrolet and GMC S Truck Models with 4 Cylinder 2.2L Engine (VINs 4, 5 - RPOs LN2, L43) This bulletin is being revised to correct the warranty information. Please discard Corporate Bulletin Number 01-06-01-030 (Section 06 - Engine/Propulsion System). Condition Some owners may comment on higher than expected engine oil consumption, therefore, having to add oil between oil changes. Important: For the LN2 and L43 engines, oil consumption greater than 1 quart (0.9 L) within 2000 miles (3200 km) is considered excessive. The oil consumption rate should be verified prior to repairs, as per Corporate Bulletin Number 01-06-01-011 dated March, 2001. Cause Two potential causes of high oil consumption have been identified: ^ The RTV seal between the stamped aluminum PCV baffle plate and the underside of the engine rocker cover may have deteriorated, allowing excessive oil mist to intrude into the PCV system. ^ The molded silicone intake manifold side gasket may have deteriorated at the PCV flow orifice, allowing excessive PCV gases to flow into the intake manifold. Correction Follow the guidelines listed under Oil Consumption Diagnosis in the Engine Mechanical section of the appropriate Service Manual, or in SI2000. If there are no other evident reasons for the concern (such as leaks), replace the rocker cover assembly with the new design cover, P/N 12570563, and replace the intake manifold side gasket with a new material gasket, P/N 12564499. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 01-06-01-030A > May > 02 > Engine Excessive Oil Consumption > Page 6766 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption Valve Cover: All Technical Service Bulletins Engine - Increased Oil Consumption File In Section: 6 - Engine Bulletin No.: 87-61-19 Date: March, 1998 Subject: Increased Oil Consumption (Replace Valve Rocker Arm Cover) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire 1998 Chevrolet and GMC S Models with 2.2L Engine (VIN 4 - RPO LN2) Built Prior to October 27, 1997 Condition Some customers may comment about increased oil consumption and having to add oil between oil changes. Cause On engines built before October 27, 1997, valve rocker arm cover baffle design may not be able to control oil flow into the foul air side of the crankcase ventilation system under certain conditions. In addition, during some high RPM operation of the engine, oil may be forced into the air cleaner duct and preplenum assembly. Correction Install a new rocker arm cover GM P/N 24577253 using procedures outlined in the appropriate Service Manual. Service Procedure 1. If the owner of the vehicle expresses concern with oil consumption, review the oil consumption rate and, if necessary, perform an oil consumption test on the vehicle. Perform an oil change, note the mileage and allow the owner to drive the vehicle for a sufficient number of miles for the engine to consume One Quart of oil. At the end of the test, review the oil consumption rate. Consumption of more than 1 quart (0.946L) within 2000 miles (3200 km) should be addressed. 2. Review the engine broadcast code label. The broadcast code label is located on the intake manifold on trucks and on the valve rocker arm cover on cars. Across the bottom of the label there will be a sequence of letters and numbers starting with the letter "T" The first five numbers in the sequence correspond to the engine build date starting with the calendar year; for example T 7 10 27 0001 = October 27, 1997. Any engine built on or after October 27, 1997, already has the revised cover in place and this bulletin does not apply. 3. Inspect the valve rocker arm cover for an identification mark (See Figure 1). The mark will be located on the rear (transmission) end of the valve rocker arm cover toward the intake manifold side of the engine. If the vehicle already has a valve rocker arm cover with this identification mark, DO NOT REPLACE THE VALVE ROCKER ARM COVER. If the vehicle has a concern with increased oil consumption, review the conditions listed in Step 5 of this bulletin and proceed with diagnostics in the engine section of the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption > Page 6771 Important: Always check engine oil on a level surface, be sure that the engine has been run until it has reached operating temperature and that the engine has been off for at least 5 minutes to allow for proper oil drain-down. If oil consumption is greater than that listed above, proceed with Step 4. 4. Install a revised valve rocker arm cover GM P/N 24577253 using procedures outlined in the Engine Mechanical Section of the appropriate Service Manual. 5. If the owner of the vehicle still has a concern with engine oil consumption after it has been determined that the latest design cover is installed. Perform further inspection of engine components for items that may cause increased oil consumption and repair as necessary. Possible causes of increased oil consumption include the following conditions: ^ External oil leaks ^ Incorrect oil level or improper reading of oil level indicator ^ Improper oil viscosity ^ Continuous high speed driving and/or severe usage such as towing, or driving in mountainous terrain ^ Blocked cylinder head, cylinder head gasket, or engine block oil drain holes ^ Valve guides and/or valve stem oil seals worn, or the seal omitted ^ Piston rings broken, improperly installed, missing, worn, or not seated properly ^ Pistons improperly installed or improperly fitted Parts Information Part Number Description 24577253 Cover, Valve Rocker Arm Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J0308 Cover and/or Gasket Rocker - Replace; 0.5 hr J Car J0308 Cover and/or Gasket Rocker - Replace; 0.8 hr S Truck Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 01-06-01-030A > May > 02 > Engine Excessive Oil Consumption > Page 6777 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 87-61-19 > Mar > 98 > Engine - Increased Oil Consumption > Page 6782 Important: Always check engine oil on a level surface, be sure that the engine has been run until it has reached operating temperature and that the engine has been off for at least 5 minutes to allow for proper oil drain-down. If oil consumption is greater than that listed above, proceed with Step 4. 4. Install a revised valve rocker arm cover GM P/N 24577253 using procedures outlined in the Engine Mechanical Section of the appropriate Service Manual. 5. If the owner of the vehicle still has a concern with engine oil consumption after it has been determined that the latest design cover is installed. Perform further inspection of engine components for items that may cause increased oil consumption and repair as necessary. Possible causes of increased oil consumption include the following conditions: ^ External oil leaks ^ Incorrect oil level or improper reading of oil level indicator ^ Improper oil viscosity ^ Continuous high speed driving and/or severe usage such as towing, or driving in mountainous terrain ^ Blocked cylinder head, cylinder head gasket, or engine block oil drain holes ^ Valve guides and/or valve stem oil seals worn, or the seal omitted ^ Piston rings broken, improperly installed, missing, worn, or not seated properly ^ Pistons improperly installed or improperly fitted Parts Information Part Number Description 24577253 Cover, Valve Rocker Arm Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J0308 Cover and/or Gasket Rocker - Replace; 0.5 hr J Car J0308 Cover and/or Gasket Rocker - Replace; 0.8 hr S Truck Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6783 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6784 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 6787 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6788 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6789 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6793 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6796 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6797 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6798 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6810 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6811 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6817 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6818 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6819 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6823 Brake Transaxle Shift Interlock (BTSI) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side > Page 6828 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Valve To Valve Body ......................................................................................................................................................... 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > 3T40 Automatic Transaxle > Page 6834 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6835 Torque Converter Clutch Solenoid: Service and Repair REMOVAL PROCEDURE 1. Remove the valve body cover. Refer to Valve Body Cover Replacement. 2. Remove the transmission mount bracket. 3. Disconnect the solenoid wire harness from the case electrical connector. 4. Disconnect the wire leads from the pressure switch. 5. Remove the torque converter clutch solenoid bolt from the control valve body. 6. Remove the 3rd clutch pressure switch. 7. Remove the 2nd clutch pressure switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6836 1. Install the 2nd clutch pressure switch, if applicable. ^ Tighten to 12 Nm (124 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install 3rd clutch pressure switch. ^ Tighten to 12 Nm (124 inch lbs.). 3. Install the torque converter clutch solenoid bolt to the control valve body. 4. Install the 0-ring. ^ Tighten to 12 Nm (124 inch lbs.). 5. Connect the wire leads to the pressure switch. 6. Connect the solenoid wire harness to the case electrical connector. 7. Install the transmission mount bracket. 8. Install the valve body cover with a new gasket. Refer to Valve Body Cover Replacement. 9. Inspect the oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle Fluid Pressure Sensor/Switch: Specifications 3T40 Automatic Transaxle Pressure Switch (S) ............................................................................................................................. ........................................................ 11 Nm (8 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > 3T40 Automatic Transaxle > Page 6843 Fluid Pressure Sensor/Switch: Specifications 4T40-E Automatic Transaxle Pressure Switch Assembly Bolts ......................................................................................................................................................... 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications > Page 6844 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6853 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6854 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6860 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6861 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6862 Transmission Position Switch/Sensor: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6863 Component Location Views On the LH rear of the transmission Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 Transmission Position Switch/Sensor: Diagrams C1 Transaxle Range Switch (C1) (Part 1 Of 2) Transaxle Range Switch (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > C1 > Page 6866 Transaxle Range Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6867 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6868 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Output Speed (Stud)-M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................................ 12 Nm (106 inch lbs.) Speed Sensor Housing To Case ............................................................................................................................................................. 11 Nm (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6872 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission Transmission Speed Sensor: Service and Repair M5 and MK7 Manual Transmission REMOVAL PROCEDURE 1. Disconnect the Vehicle Speed Sensor (VSS) lead from the transaxle. 2. Remove the VSS bolt. 3. Remove the VSS retainer. 4. Remove the VSS assembly. 5. Remove the O-ring. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6875 1. Lubricate a new O-ring with synchromesh transaxle fluid GM P/N 12345349 or equivalent. 2. Install the new O-ring. 3. Install the Vehicle Speed Sensor (VSS) assembly. 4. Install the VSS retainer. 5. Install the VSS bolt. ^ Tighten the bolt to 9 Nm (80 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 6. Connect the VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6876 Transmission Speed Sensor: Service and Repair 4T40-E Automatic Transaxle REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector. 3. Remove the vehicle speed sensor bolt. 4. Remove the vehicle speed sensor from the case extension. 5. Remove the O-ring from the vehicle speed sensor. INSTALLATION PROCEDURE 1. Install the O-ring onto the vehicle speed sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > M5 and MK7 Manual Transmission > Page 6877 2. Install the vehicle speed sensor into the case extension. 3. Install the vehicle speed sensor bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). NOTICE: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored ABS Light: Testing and Inspection ABS Warning Lamp Always ON, No DTC's Stored ABS Indicator On No DTC Set Wiring Diagram ABS Indicator On No DTC Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBC and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 6884 With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ABS warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 6885 ABS Light: Testing and Inspection ABS Warning Lamp OFF Constantly, No DTC's Stored ABS Indicator Off No DTC Set Wiring Diagram ABS Indicator Off No DTC Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The following conditions may cause an intermittent malfunction: ^ A poor connection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 6886 ^ Rubbed-through wire insulation ^ A broken wire inside the insulation The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed, refer to Instrument Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ABS warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Component Locations Brake Fluid Pump: Component Locations At the left rear of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Component Locations > Page 6894 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Page 6895 ABS Actuator Motor Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Technical Service Bulletins > Twist-Lock Style Brake Switches - Proper Adjustment Braking Sensor/Switch: Technical Service Bulletins Twist-Lock Style Brake Switches - Proper Adjustment File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-12 Date: April, 1998 INFORMATION Subject: Proper Adjustment of New Twist-Lock Style Brake Switches Models: 1996-98 Buick LeSabre, Park Avenue, Riviera 1996-98 Cadillac DeVille, Eldorado, Seville 1997-98 Chevrolet Malibu 1998 Chevrolet Cavalier 1996 Oldsmobile Ninety Eight 1996-98 Oldsmobile Aurora, Eighty Eight, LSS, Regency 1997-98 Oldsmobile Cutlass 1999 Oldsmobile Alero 1996-98 Pontiac Bonneville 1998 Pontiac Sunfire 1999 Pontiac Grand Am This bulletin is being issued to advise that new style brake switches were used beginning in the 1996 model year. The two switches control the brake lights, cruise control engage/release, TCC lock-up/release and the Brake/Transmission Inter-Lock function. The switches are adjusted by twisting rather than ratcheting. Using the old adjustment method of pulling up on the brake pedal can break the switch. A mis-adjusted or damaged switch may cause customer comments such as: ^ Brake lights stay on, draining the battery ^ Cruise control inoperative ^ Higher than normal fuel consumption if TCC cannot engage ^ Brake drag ^ Cruise control takes excess pedal travel to release The adjustment procedure in the Service Manual should be followed. Procedure 1. Insert the stop lamp switch into the retainer until the switch bottoms out against the brake pedal, and the switch actuator is fully depressed. 2. Turn the brake switch in the retainer clockwise until the travel stop has been reached. At this point it will be locked. Important: If the switch is not fully locked into position, a clicking noise may result. 3. The brake switch plunger should extend outward 0.5 mm to 1.5 mm (0.02 in. to 0.06 in.) if adjusted correctly. 4. If the distance the plunger extends is too great, the brake switch must be turned counter-clockwise about 45° and set to the correct distance before locking it in place by turning it clockwise until the travel stop is reached. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6908 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6909 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6915 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6916 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6917 Electronic Brake Control Module: Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6918 Component Location Views Left hand lower I/P Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module (EBCM) (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 6921 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM) (C2) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 6922 Electronic Brake Control Module (EBCM) (C2) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement REMOVAL PROCEDURE 1. Remove the dash wiring harness connectors from the EBCM. 2. Remove the EBCM from the bracket. INSTALLATION PROCEDURE 1. Install the EBCM to the bracket. 2. Install the dash wiring harness connectors to the EBCM. 3. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement > Page 6925 Electronic Brake Control Module: Service and Repair Electronic Brake Control Relay Replacement REMOVAL PROCEDURE 1. Remove the underhood fuse block cover. 2. Remove the electronic brake control relay from the underhood fuse block. INSTALLATION PROCEDURE 1. Install the electronic brake control relay into the underhood fuse block. 2. Install the underhood fuse block cover. 3. Perform the "Diagnostic System Check" in Antilock Brake System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Specifications Hydraulic Assembly: Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 6931 Hydraulic Assembly: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 6932 LF And RF ABS Solenoid And ABS Actuator Motor Assembly Connectors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 6933 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 6934 Brake Fluid Level Indicator And Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 6935 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Page 6936 Hydraulic Assembly: Diagrams LF ABS Solenoid RF ABS Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement Hydraulic Assembly: Service and Repair ABS Motor Pack Replacement REMOVAL PROCEDURE 1. Remove the gear cover (3). Important: ^ Use care when handling the motor pack to avoid damaging the motor pack connector. Make sure brake fluid does not accidentally intrude into the motor pack. Brake fluid in the motor pack may cause a premature failure of the motor pack. ^ Use care when handling the motor packs. Replace the motor packs if the motor packs are dropped or damages during handling. 2. Remove the Torx head screws (5) that attach the motor pack (1). 3. Remove the motor pack assembly (1). Important: If the disassembly of the modulator/master cylinder assembly was caused by an ABS or ETS hydraulic functional test that did not pass, the Automated ABS brake motor pack Diagnosis Test should be performed. Refer to Scan Tool diagnostics in Antilock Brake System. The Automated ABS brake motor pack Diagnosis Test isolates the motor pack or brake modulator. No repair of the motor pack is authorized. Replace as an assembly. INSTALLATION PROCEDURE 1. With the modulator positioned upside down, rotate each ABS brake modulator gear counterclockwise until movement stops. The above procedure will cause the following conditions: ^ The pistons on the ABS brake modulator will be positioned very close to the top of the modulator bore. ^ The brake bleeding procedure becomes simplified. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6939 IMPORTANT: Use care when handling the motor packs. Replace the motor packs if the motor packs are dropped or damaged during handling. Align each of the three motor pack pinions with the modulator gears. 2. Install the motor pack (1) to the modulator assembly (6). 3. Install Torx head screws (4). ^ Tighten the Torx head screws to 4.5 Nm (40 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the gear cover (3) onto the modulator/brake master cylinder assembly. 5. Perform Motor Rehome Procedure. 6. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6940 Hydraulic Assembly: Service and Repair Brake Modulator Gear Replacement REMOVAL PROCEDURE CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing brake modulator drive gear cover, exercise extreme care not to place fingers intor the gear set, since fingers can be pinched by rotating gears. NOTICE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. IMPORTANT: Do not repair damaged motor packs or brake modulators. Other than modulator drive gears replacement, repair of the motor pack and brake modulator assemblies is not authorized. Do not oil or lubricate the gears on the motor pack. 1. Remove the brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly. 2. Remove the Torx head screws that attach the gear cover. 3. Remove the motor pack to modulator Torx head screws. Important: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling. 4. Separate the motor pack from the modulator. 5. Remove three modulator drive gear retaining nuts. 6. Remove the gears from the modulator. INSTALLATION PROCEDURE 1. Position the modulator drive gears onto the modulator drive shaft. Notice: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6941 2. Install three gear retaining nuts. ^ Tighten the nuts to 8.5 Nm (75 inch lbs.). 3. With either of the modulators positioned upside down, and the gears facing your, rotate each ABS brake modulator gear counterclockwise until movement stops. Rotating the modulator gears will cause the following conditions: ^ The pistons on the ABS brake modulator will be positioned very close to the top of the modulator bore. ^ The brake bleeding procedure is simplified. Important: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling. 4. Position the motor pack onto the modulator, aligning the three motor pack gears with the modulator gears. 5. Install motor pack to modulator Torx head screws. ^ Tighten the Torx head screws to 4.5 Nm (40 ft. lbs.). 6. Install the gear cover onto the modulator with Torx head screws. ^ Tighten the Torx head screws to 4 Nm (45 inch lbs.) 7. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly. 8. Perform the Motor Rehome Procedure. 9. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6942 Hydraulic Assembly: Service and Repair Brake Modulator Replacement REMOVAL PROCEDURE 1. Remove the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement. 2. Remove the Torx head screws (5) attaching the gear cover (4). 3. Remove the gear cover (4). 4. Remove the four Torx head screws (6) attaching the motor pack (1) to the brake modulator (2). 5. Remove the motor pack (1) from the brake modulator (2). 6. Remove the two brake modulator to master cylinder banjo bolts, separate the brake modulator from the master cylinder. 7. Remove the two transfer tubes with the O-rings from the master cylinder or the brake modulator. 8. Remove the banjo bolt O-rings from the master cylinder and the brake modulator. INSTALLATION PROCEDURE IMPORTANT: When replacing the ABS brake modulator, install the three gears in the same location on the replacement brake modulator. Refer to Brake Modulator Gear Replacement in Hydraulic Assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6943 No repair of the ABS brake modulator is authorized. Replace the ABS brake modulator as an assembly. IMPORTANT: Use new transfer tube assemblies when assembling the ABS brake modulator/master cylinder assembly. Be sure to properly install two O-rings on each transfer tube. 1. Use the following procedure in order to install the two transfer assemblies: 1.1. Lubricate the transfer tube assembly O-rings with clean brake fluid. 1.2. Install the transfer tube assemblies into ports of the ABS brake modulator. Push the tube assemblies in by hand to the bottom of the ports. 2. Lubricate the new banjo bolt 0-ring with clean brake fluid. 3. Install the banjo bolt 0-ring into the master cylinder and the ABS brake modulator. 4. Use the following procedure in order to install the ABS brake modulator onto the master cylinder: 4.1. Clamp the mounting flange of the master cylinder in a vise. 4.2. Hold the ABS brake modulator and rock the modulator into position on the master cylinder. 4.3. Insert the transfer tube assemblies into the master cylinder ports. 5. Install two ABS brake modulator to master cylinder banjo bolts. Tighten Tighten the banjo bolts to 24 Nm (18 ft. lbs.). 6. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until movement stops. The procedure causes the following conditions: ^ The pistons are positioned very close to the top of the modulator bore. ^ The brake bleeding procedure is simplified. 7. Install the ABS brake motor pack (1) onto the brake modulator/master cylinder assembly (2). 8. Install the four Torx head screws (6) that retain the motor pack (1) to the brake modulator (2). Tighten Tighten the four Torx head screws to 5 Nm (44 inch lbs.). 9. Install the gear cover (4) to the brake modulator/master cylinder assembly (2). 10. Install the Torx head screws (5) that retain the gear cover (4). Tighten Tighten the Torx head screws to 4 Nm (36 inch lbs.). 11. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement 12. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6944 Hydraulic Assembly: Service and Repair Modulator Gear Cover Replacement REMOVAL PROCEDURE 1. Remove the Torx head screws (4) that attach the gear cover (3). 2. Remove the gear cover (3). INSTALLATION PROCEDURE 1. Install the gear cover (3) onto the modulator/master cylinder assembly. 2. Install the Torx head screws (4). ^ Tighten the Torx screws to 4 Nm (36 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 6945 other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6954 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6955 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6961 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 6962 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator ON With No DTCS Set ETS Off Indicator On No DTCs Set Wiring Diagram ETS Off Indicator On No DTCs Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The ETS OFF indicator will be ON and the Enhanced Traction System will be disabled whenever the scan tool is connected to the DLC with the ignition switch is in the RUN position. The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 6967 portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Panel Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ETS OFF warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 6968 Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator OFF No DTCS Set ETS Off Indicator Off No DTCs Set Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 6969 ETS Off Indicator Off No DTCs Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM\A and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Panel luster for further serial data link information. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool, as described in "Enhanced Diagnostics". The following conditions may cause an intermittent malfunction: ^ A poor connection ^ Rubbed-through wire insulation ^ A broken wire inside the insulation Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ETS OFF warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component Location Views At the center console on the gear selector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 6973 Enhanced Traction Control System Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Retaining Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor Wheel Speed Sensor: Locations Wheel Speed Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 6979 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 6980 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF LF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 6983 RF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 6984 LR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 6985 RR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Disconnect the front wheel speed sensor electrical connector. 3. Remove the retaining bolt. 4. Remove the front wheel speed sensor. If the sensor will not slide out of the knuckle, remove the brake rotor and use a blunt punch or equivalent tool to push the sensor from the back side of the knuckle. IMPORTANT: If the sensor locating pin breaks off and remains in the knuckle during removal, proceed as follows: 1. Remove the brake rotor and remove broken pin using a blunt punch. 2. Clean the hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALLATION PROCEDURE 1. Install the front wheel speed sensor to the steering knuckle. 2. Install the retaining bolt. ^ Tighten the Torx screws to 12 Nm (107 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Connect the front wheel speed sensor electrical connector. 4. Lower the vehicle. 5. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 6988 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) IMPORTANT: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Rear Suspension in Suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 6989 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Remove the connector from the front wheel speed sensor. 3. Remove the harness attaching clips (2) from the control arm (3) and the splash shield (1). 4. Lower the vehicle. 5. Remove the harness attaching clips from the strut tower. 6. Cut the wheel speed sensor wiring circuits within the main engine harness. 7. Strip the insulation on the engine harness leads and the new wheel speed sensor harness leads. INSTALLATION PROCEDURE 1. Splice the sleeve provided in the jumper harness kit over each engine harness lead. 2. Install the new wheel speed sensor harness leads to the engine harness leads and crimp the connections. Make sure the wire colors match. 3. Heat shrink the tube lightly to seal the connection. 4. Install the harness attaching clip to the strut tower. 5. Raise and support the vehicle. Refer to Vehicle Lifting And Jacking. 6. Install the harness attaching clips (2) to the control arm (3) and the splash shield (1). 7. Install the connector to the front wheel speed sensor. 8. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 9. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 6990 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement (Rear Axle) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting and Jacking. 2. Disconnect the two rear wheel speed sensor electrical connectors (3) from the rear wheel bearing and speed sensor assemblies (2). 3. Disconnect the rear axle harness electrical connector from the body to ABS and fuel sender connector. 4. Remove the rear axle harness retainers (1). 5. Remove the rear axle harness from the vehicle. INSTALLATION PROCEDURE 1. Install the rear axle harness to the vehicle. 2. Install the rear axle harness retainers (1). 3. Connect the rear axle harness electrical connector to the body to ABS and fuel sender connector. 4. Connect the two rear wheel speed sensor electrical connectors (3) to the rear wheel bearing and speed sensor assemblies (2). 5. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 6. Perform the Diagnostic System Check. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure Brake Bleeding: Service and Repair Motor Rehome Procedure REHOME TEST The motor rehome function will return all of the hydraulic modulator pistons to their upmost home, position. This allows all fluid paths within the modulator to be open so that the modulator can be properly bled. The motor rehome function must ALWAYS be used prior to bleeding the brake system IMPORTANT: The motor rehome function cannot be performed if any current DTCs are present. If current DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 6995 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding CAUTION: Do not move the vehicle until a firm brake pedal is obtained. Air In the brake system can cause the loss of brakes with possible personal injury. A bleeding operation is necessary in order to remove air from the hydraulic brake system whenever air is introduced into the brake system. Bleed the hydraulic system at all four brakes if air has been introduced into the system through low fluid level or by disconnecting the brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, bleed only that wheel cylinder/caliper. If the pipes are disconnected at any fitting located between the master cylinder and brakes, bleed the brake system served by the disconnected pipe. Observe the following steps in order to reduce the time required to bleed the hydraulic system: ^ Ensure that the master cylinder reservoir is filled with brake fluid. ^ Expel as much air as possible before installing the master cylinder on the vehicle. MANUAL BLEEDING Tools Required ^ J 21472 Brake Bleeder Wrench Apply the brakes several times with the ignition OFF. This will deplete the vacuum reserve. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with the specified brake fluid in Maintenance and Lubrication in General Information. ^ Maintain the fluid level in the reservoir during the bleeding operation. ^ Use an assistant in the vehicle in order to press the brake pedal during the manual bleeding process. 2. If the master cylinder is known or suspected to have air in the bore, bleed the master cylinder before the wheel cylinder or the calipers are bled. Complete the following steps: 3. Disconnect the forward brake pipe connections) (1) at the master cylinder. 4. Fill the master cylinder with brake fluid until fluid begins to flow from the forward pipe connector port. 5. Connect the forward brake pipe to the master cylinder. Tighten the pipe. 6. Slowly depress the brake pedal and hold the pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 6996 7. Loosen the forward brake pipe connection at the master cylinder in order to purge air from the cylinder. 8. Tighten the connection. 9. Slowly release the brake pedal. 10. Wait 15 seconds. 11. Repeat the previous eight steps until all air is removed from the bore. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 12. Bleed the master cylinder at the rear (cowl end) connections after all the air has been removed at the forward connections. Slowly depress the brake pedal and hold the pedal. 13. Check for a firm pedal feel and proper brake pedal travel. If the wheel cylinders and calipers do not contain air, bleeding is not necessary, but recommended in order to remove any moisture or debris. 14. After all air is removed from the master cylinder, bleed the wheel cylinders in the following order, if necessary: 14.1. Right rear 14.2. Left rear 14.3. Right front 14.4. Left front 15. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 16. Place a proper size box end wrench (1) (or special tool) over the caliper/cylinder bleeder valve. 17. Attach a transparent tube (2) over the bleeder screw. Submerge the other end in a transparent container partially filled with clean brake fluid. 18. Slowly depress the brake pedal and hold the pedal. 19. Loosen the bleeder screw in order to purge the air from the cylinder/caliper. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 20. Tighten the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (62 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm (115 inch lbs.). 21. Slowly release the pedal. 22. Wait 15 seconds. 23. Repeat the previous five steps until all air is removed from the caliper. Do not pump the brake pedal rapidly. Pumping the pedal pushes the master cylinder secondary piston down the bore which causes difficult bleeding. 24. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 6997 25. Fill the master cylinder to the proper level. 26. Check the brake pedal for sponginess or excessive travel. Repeat the entire manual bleeding procedure in order to correct either of the two conditions. PRESSURE BLEEDING Tools Required ^ J 29532 Diaphragm Type Brake Bleeder ^ J 35589 pressure Bleeder Adapter Cap ^ J 21472 Brake Bleeder Wrench NOTICE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install the J 35589 to the master cylinder 2. Charge the J 29532 to 140-172 kPa (20-25 psi). 3. Connect the line to the J 35589. 4. Open the line valve. 5. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 6. Bleed the wheel cylinders/calipers in the following order, if necessary: 6.1. Right rear 6.2. Left rear 6.3. Right front 6.4. Left front 7. Place the J 21472 over the caliper/cylinder bleeder valve. 8. Attach a transparent tube over the bleeder screw. Submerge the opposite hose end in a transparent container partially filled with clean brake fluid. 9. Open the bleeder screw at least 3/4 of a turn. Allow the fluid to flow until no air is visible in the fluid. 10. Close the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (6.2 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm ( 115 inch lbs.). 11. Repeat the previous four steps until all of the calipers/cylinders have been bled. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 6998 12. Lower the vehicle. 13. Inspect the brake pedal for sponginess. Repeat this entire pressure bleeding procedure in order to correct this conditions. 14. Remove the J 35589 and the J 29532. 15. Fill the master cylinder to the proper level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal to Bracket ........................................................................................................................ .................................................... 27 N.m (20 ft. lbs.) Brake Pedal Travel * ............................................................................................................................ ................................................ 63.5 mm (2.5 inches) * Note: Brake pedal travel maximum with 445 N (100 lbs.) force applied to pedal with ignition OFF and vacuum assist deleted. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7002 Brake Pedal Assy: Testing and Inspection ^ Tools Required J 28662 Brake Pedal Effort Gauge 1. With the engine off and the key OFF, pump the service brake pedal until all reserve is exhausted from the brake booster. 2. Install the J 28662 or the equivalent onto the brake pedal. 3. Hook the end of the tape measure over the top edge of the pedal. 4. Measure the distance from the top edge of the brake pedal to the rim of the steering wheel. 5. Depress the service brake pedal with approximately 445 N (100 lbs.) of force. 6. Re-measure the distance from the top edge of the brake pedal to the rim of the steering wheel. The difference between both readings is the actual pedal travel and should not exceed 63 mm (2.5 in). 7. If the pedal travel is greater than 63 mm (2.5 in), drive the vehicle backward while intermittently applying the brakes. In rare cases, excessive pedal travel will develop if brakes are only used occasionally when backing up. This will develop when the vehicle is only driven in reverse. Duo-Servo self-adjusting mechanisms will only actuate when the brakes are applied in reverse. 8. Air in the hydraulic system may be the cause of most low pedal problems. Bleed the system until all air is purged. Refer to Brake Bleeding. 9. Other less frequent causes of excessive brake travel include the following conditions: ^ Incorrect brake booster pushrod length ^ Improperly adjusted parking brake ^ Rear shoe adjusters not functioning ^ Shoes excessively worn ^ Hydraulic system leakage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7003 Brake Pedal Assy: Service and Repair REMOVAL PROCEDURE 1. Remove the left sound insulator panel. 2. Disconnect the pushrod from the brake pedal (10). 3. Disconnect the accelerator cable. 4. Remove the brake pedal assembly (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7004 5. Disconnect the electrical connections (1,2). INSTALLATION PROCEDURE 1. Connect the electrical connections (1, 2). 2. Install the brake pedal assembly (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7005 3. Connect the accelerator cable. 4. Connect the pushrod to the brake pedal (10). 5. Install the left sound insulator panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 Brake Warning Indicator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Page 7042 Brake Warning Indicator: Description and Operation The standard brake system uses a single red BRAKE warning light. The light is located in the instrument panel cluster. When the ignition switch is in the START position, the BRAKE warning light should glow and turn off when the ignition switch returns the RUN position. The following conditions will activate the BRAKE light: ^ The parking brake is applied. The light should be on whenever the parking brake is applied and the ignition switch is on. ^ The fluid level is low. A low fluid level in the master cylinder will turn the BRAKE light on. For electrical diagnosis on the BRAKE warning system, refer to Brake Lamp (Warning Indicator). Antilock Brake System The antilock brake system uses two indicator lamps, a red BRAKE warning lamp and an amber ANTILOCK lamp. Both of the lamps are located in the instrument panel cluster. The lamps should activate under the following normal conditions: ^ When the ignition is turned to the RUN position, prior to starting the engine, the amber ANTILOCK lamp should fun ON. ^ As the engine is cranked, the red BRAKE lamp and the amber ANTILOCK lamp should come ON. ^ When the engine is started, both lamps should be OFF. For further information regarding the warning lamp operation for the Antilock brake system, refer to ABS Light. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleeder Screws 115 in.lb Caliper Inlet Fitting 34 ft.lb Caliper Mounting Bolts 38 ft.lb Caliper Bore Diameter 2.244 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement Brake Caliper: Service and Repair Brake Caliper Replacement REMOVAL PROCEDURE 1. Remove 2/3 of the brake fluid from the master cylinder assembly. 2. Raise the vehicle and suitably support the vehicle. 3. Mark the relationship of the wheel to the hub and bearing assembly in order to ensure proper wheel balance upon reassembly. 4. Remove the tire and wheel assembly. Refer to Wheel Removal. Reinstall two wheel nuts in order to retain the rotor to hub and bearing assembly. 5. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor. 6. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough in order to slide the caliper assembly off the rotor. 7. Remove the bolt attaching inlet fitting (5) only when the caliper (2) is to be removed from the vehicle for unit repair (overhaul). If only the shoe and linings are being replaced, there is no need to disconnect the inlet fitting (5). Plug the exposed inlet fitting (5) in the caliper housing and the brake hose to prevent fluid loss and contamination. 8. Remove the caliper mounting bolts (1) and sleeve assemblies. 9. Remove the caliper from the rotor and knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7049 ^ Do not let the caliper (2) hang from the brake hose. Damage may occur. ^ If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut (1). 10. Inspect the mounting bolts (1) and sleeve (4) assemblies for corrosion. 11. Inspect the bushings (2) for cuts and nicks. 12. If damage to either part is found, replace with new parts when installing the caliper. 13. Do no attempt to polish away corrosion. INSTALLATION PROCEDURE 1. Liberally coat the inside of the diameter of the bushings (4) with silicone grease (4). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the mounting bolts (1) and sleeve (4) assemblies (1). 3. Install the caliper (2) over the rotor into the knuckle. ^ Tighten the mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7050 4. Install the inlet fitting, if the inlet fitting was removed. ^ Tighten the inlet fitting to 44 Nm (32 ft. lbs.). 5. Perform the following steps in order to install the wheel and tire, aligning the previous marks: 5.1. Remove the wheel nuts securing the rotor to the hub and bearing assembly. 5.2. Install the wheel and tire assembly with the retaining nuts in the proper sequence. Refer to Wheel Installation. 5.3. Lower the vehicle. 5.4. Tighten the wheel nuts. Refer to Wheel Fastner Specifications. 6. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 6.1. Bleed the caliper if the inlet fitting was removed. Refer to Brake Bleeding in Hydraulic Brakes. 6.2. Recheck the fluid level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 6.3. Recheck the brake pedal feel. If brake spongyness is present, refer to Brake System Testing and Inspection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7051 Brake Caliper: Service and Repair Brake Caliper Overhaul REMOVAL PROCEDURE 1. Remove the caliper completely from the vehicle. Refer to Brake Caliper Replacement. 2. Disassemble the bushings (6). 3. Inspect the bushings (6) for cuts and nicks. Replace the bushings (6) if damaged. CAUTION: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. IMPORTANT: Use clean shop towels in order to pad the interior of the caliper housing during the removal. 4. Remove the piston using compressed air into the caliper inlet hole (1). 5. Inspect the piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace the piston if any of these conditions are found. 6. Remove the boot (2) from the caliper housing bore. Be careful not to scratch the housing bore. Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result. 7. Remove the piston seal grove in the caliper housing bore with a small wood or plastic tool. 8. Inspect the caliper housing bore and seal groove for scoring, nicks, corrosion and wear. 9. Use a crocus cloth to polish out light corrosion. 10. Replace the caliper (1) housing if corrosion in and around the seal groove will not clean up with a crocus cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7052 11. Remove the bleeder valve and bleeder valve (5) cap from the caliper. 12. Clean all parts in clean, denatured alcohol. 13. Dry the parts with unlubricated compressed air. 14. Blow out all passages in the caliper housing and bleeder valve. INSTALLATION PROCEDURE Tools Required ^ J29077-A Front Disc Brake Caliper Dust Boot Installer NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Assemble the bleeder valve (5) and bleeder valve cap into caliper. ^ Tighten the bleeder valve to 13 Nm (115 inch lbs.). 2. Lubricate the new piston seal (2) and install the new piston seal into the caliper bore groove. 3. Make sure the seal (2) is not twisted. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7053 4. Install the lubricated boot (2) onto the piston (1). 5. Install the piston and boot onto the bore of the caliper and push to the bottom of the bore. 6. Seat boot fin the caliper housing counter bore using J29077-A. 7. Perform the following steps in order to install the bushings: 7.1. Lubricate the beveled end of the bushing with silicone grease, or the equivalent. 7.2. Pinch the bushing and install the bevel end first. 7.3. Push the bushing through the housing mounting bore. 8. Install the caliper. Refer to Brake Caliper Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications 1. Inspect the brake linings every 9654 km (6,000 miles). 2. Inspect the brake linings whenever removing the tire and wheel assembly, such as a tire rotation. 3. Check both ends of the outer pad by looking in at each end of the caliper. These are the points at which the highest rate of wear normally occurs. 4. Check the lining thickness on the inner shoe for premature wear. The inboard shoe and linings may have a thermal layer against the shoe which is molded with the lining. Do not confuse this layer with uneven inboard outboard lining wear. 5. Look down through the inspection hole in the top of the caliper in order to view the inner shoe. 6. Replace the disc brake shoe and lining assemblies when the thickness of any lining is worn to within 0.76 mm (0.030 in) of the shoe. For riveted shoe and lining assemblies, replace the lining if it is worn to within 0.76 mm (0.030 in) of any rivet head. 7. Replace all disc brake shoe and lining assemblies at the same time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 7057 Brake Pad: Testing and Inspection 1. Inspect the brake linings every 9654 km (6,000 miles). 2. Inspect the brake linings whenever removing the tire and wheel assembly, such as a tire rotation. 3. Check both ends of the outer pad by looking in at each end of the caliper. These are the points at which the highest rate of wear normally occurs. 4. Check the lining thickness on the inner shoe for premature wear. The inboard shoe and linings may have a thermal layer against the shoe which is molded with the lining. Do not confuse this layer with uneven inboard outboard lining wear. 5. Look down through the inspection hole in the top of the caliper in order to view the inner shoe. 6. Replace the disc brake shoe and lining assemblies when the thickness of any lining is worn to within 0.76 mm (0.030 in) of the shoe. For riveted shoe and lining assemblies, replace the lining if it is worn to within 0.76 mm (0.030 in) of any rivet head. 7. Replace all disc brake shoe and lining assemblies at the same time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 7058 Brake Pad: Service and Repair The GM replacement brake lining material is recommended for all GM vehicles. This is done in order to maintain the balance between front and rear brake performance. GM replacement parts have been carefully selected in order to provide the proper brake balance for purposes of both stopping distance and controllability over the full range of operation conditions. Installation of the front or rear brake lining material with performance different from that of the GM replacement parts recommended for this vehicle may change the intended brake balance of this vehicle. . Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7063 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7064 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7065 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7066 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7067 Brake Align Order Form Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7068 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor & Hub Flange Cleaning Tool Revision File In Section: 5 - Brakes Bulletin No.: 73-50-37 Date: January, 1998 INFORMATION Subject: Revision to J 42450 Tool; Proper Brake Rotor and Hub Flange Surface Cleaning Models: 1998 and Prior Passenger Cars and Light Duty Trucks - with Disc Brakes (Rotor and Hub Separate) This bulletin is being revised to update the following text. This bulletin is being issued to inform the dealer about a revision to tool J 42450 and reinforce the need for proper hub flange and brake rotor mating surface cleaning during service. Tool J 42450 is a cleaning pad arbor and pad system that fits over the wheel stud and cleans the portion of the hub surface that is very difficult to reach with normal rotary cleaning pads. Tool J 42450 is being revised to J 42450-A to improve the hook and loop material retention. Any dealer experiencing problems with tool J 42450 should contact Kent-Moore at 1-800-345-2233 for a revised arbor at no charge. Anytime the brake rotor has been separated from the hub bearing flange or if rotor machining is necessary, the rotor and hub should be marked to maintain the original position. Clean the hub flange of all dirt and foreign material using special tool J 42450 or J 42450-A. Clean both sides of the brake rotor hub using an aggressive (80 grit) abrasive sanding pad on a rotary disc. Properly cleaning the rotor surfaces before rotor machining or reassembly ensures that dirt and corrosion will not add lateral runout to the rotor. Proper cleaning of the hub flange will also minimize the stack-up of lateral runout. On reassembly, the rotor should be reinstalled aligning the marks made on disassembly. Always use a torque wrench or the appropriate Torque Socket found in J 39544-KIT on an impact wrench when installing the wheel and tire assembly. Torque all wheel nuts using the correct sequence and torque. Refer to the Tire and Wheel Sub-Section in the applicable Service Manual. Excessive torque or torque variation between wheel nuts may cause distortion of the hub and rotor mating surface. This distortion may cause lateral runout and lead to brake pulsation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7069 Technical Service Bulletin # 23-50-05B Date: 971101 Brakes - Rotor Warranty Service Procedure File In Section: 5 - Brakes Bulletin No.: 23-50-05B Date: November, 1997 INFORMATION Subject: Brake Rotor Warranty Service Procedure Model: 1994-98 GM Passenger Cars This bulletin outlines GM's procedures for brake rotor service for all applicable GM passenger cars and supersedes Corporate Bulletin Number 23-50-05A Section 5 - Brakes). Important: Rotors should only be turned when one or more of the following rotor surface conditions exist: 1. Severe Scoring - depth in excess of 1.5 mm (0.060 in.). 2. Pulsation Concerns from: a. Thickness variation in excess of 0.025 mm (0.001 in.). b. Corrosion on rotor braking surfaces. Rotors are NOT to be resurfaced in an attempt to correct: 1. Noise/squeal. 2. Cosmetic corrosion. 3. Routine pad replacement. 4. Discoloration and/or "hard spots". Explanation of Brake Rotor Warranty Service Procedure Research and testing has determined: 1. Rotor refacing during normal pad replacement is not necessary. 2. Rotor refacing for cosmetic corrosion is unnecessary. Clean-up of braking surfaces can be accomplished by 10-15 moderate stops from 62-75 km/h (35-40 mph) with cooling time between stops. 3. Rotor service is ineffective in correcting BRAKE SQUEAL, and/or PREMATURE LINING WEAR OUT, and should NOT be used to address these conditions. 4. When installing new rotors, DO NOT reface them. 5. Ensure bearing flanges are free of corrosion when installing rotors to prevent inducing lateral runout. Use Kent Moore tool J 42450 to clean the corrosion around the wheel studs. Brake Service Techniques EVERY brake service should include: 1. Clean and lube all metal-to-metal contact points (i.e.; caliper to knuckle, pad to knuckle, etc.). 2. Clean and lube slide pins. 3. Set correct clearances - caliper to knuckle, etc. 4. Clean rotor and hub mounting surfaces. Use Kent Moore tool J 42450 to clean around wheel studs. Pulsation Brake pulsation concerns may result from two basic conditions: 1. Thickness variation. 2. Excessive corrosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7070 Rotor thickness variation is the result of uneven rotor wear caused by excessive lateral runout (>0.076 mm; >0.003 in.). Lateral runout can be induced by: 1. Distortion of the braking surface by applying uneven and/or excessive wheel nut torque. (This could be the result of a recent tire change, rotation, etc.). 2. Improperly refacing rotors. Brake Noise Important: SOME BRAKE NOISE IS NORMAL. Brake noise is caused by a "slip stick" type vibration of brake components. Some intermittent brake noise may be normal. Performing 3-4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists, a brake dampening compound may be applied to the back of each pad. Use Permatex Disc Brake Quiet # 126HB or equivalent. Also, clean and lube all metal-to-metal contact areas between pads, pad guides, caliper and knuckles with a thin layer of high temperature silicone grease. This allows parts to slide freely and not vibrate when moving relative to each other. Rotor Grooving Excessive grooving can be caused by foreign material in contact with the rotor, but most often rotor grooving is the result of normal brake wear. DO NOT RESURFACE ROTORS FOR LIGHT GROOVING. Resurface rotors only when grooves of 1.5 mm (0.060 in.) or deeper are present. A dime may be used to determine disc brake groove depth. Place a dime in the groove, with Roosevelt's head toward the groove. If the dime goes into the groove beyond the top of his head, the groove exceeds 1.5 mm (0.060 in.) and the rotor should be serviced. (In Canada, if any portion of the letters of "In Canada" are covered, the rotor should serviced.) It the groove is too narrow for the dime to be inserted, it is not a cause for concern. High Pedal Effort Follow Service Manual diagnostic procedures for this condition. Service rotors if they have been recently resurfaced. (The surface finish may be out-of-specification). Lightly Rusted Rotors Light surface rust on rotor braking surfaces is often cosmetic and can be eliminated during a few normal driving stops. Rusting may occur when a vehicle is not driven for extended periods. Rotors with surface rust on unsold new cars can usually be burnished clean by performing 15 moderate stops from 62-75 km/h (35-40 mph) with cooling time between stops. Facts About Brake Service ^ Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. New rotors should not be resurfaced before installation. ^ Improper tightening of wheel nuts can induce lateral runout (distortion of braking surfaces) which will lead to uneven wear. As high spots are worn down, resulting thickness variation will cause brake pulsation. ^ Ensure wheel bearing flange is clean and free of corrosion before installing new rotors. A new essential tool (Kent Moore tool J 42450) will soon be sent to all dealers. This tool makes it easier to clean corrosion around the wheel studs. ^ Always mark the position of rotor on the hub before removal, and reinstall the rotor in the same position. ^ Rotors with perceived hard spots or discoloration should not be serviced. These conditions are normal. ^ Installation of new rotors does not require pad replacement. Do NOT replace pads unless their condition requires it. ^ It is NOT necessary to replace rotors in pairs. Rotors may be serviced individually. ^ A TORQUE LIMITING SOCKET OR TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in 3 steps using the star pattern. 1. Snug the nuts down by hand. 2. Using the star pattern and a torque limiting socket or torque wrench, tighten the wheel nuts to about half the final torque. 3. Tighten the wheel nuts to specification using the star pattern and a torque limiting socket or torque wrench. ^ NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 7071 Brake Rotor/Disc: Specifications Rotor Diameter 10.197 in Lateral Runout 0.003 in Thickness Variation 0.0005 in Rotor Thickness (Maximum) 0.786 in Minimum Thickness After Refinish 0.751 in Discard Thickness 0.736 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Lateral Runout Check Brake Rotor/Disc: Testing and Inspection Brake Rotor Lateral Runout Check NOTICE: Whenever the brake rotor has been separated from the wheel bearing flange, clean any dust or foreign material from the mating surface of the rotor and flange. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Check the lateral runout with the wheels still installed on the vehicle. This gives a much more accurate reading of the Total Indicated Runout (T.I.R.) under real braking conditions. If equipment is not available to perform the check with the wheels installed. If leaving the wheels on the vehicle is not possible. Check with the caliper still installed. 1. Clean the rotor surface. IMPORTANT: If the wheel must be removed, reinstall the wheel nuts to retain the rotor. Tighten the wheel nuts to the correct tightening specifications following the wheel nut tightening sequence. 2. Fasten a dial indicator to the steering knuckle so that the indicator button contacts the rotor surface about 13 mm (0.5 in) from the outer edge. 3. Set the dial indicator to zero. 4. Turn the wheel one complete revolution. 5. Observe the runout indicated on the dial. The total indicated runout (T.I.R.) must not exceed 0.008 mm (0.003 in). 6. Refinish or replace the rotor if the lateral runout exceeds the amount specified in the previous step. Occasionally excessive lateral runout of the rotor may be improved by indexing the rotor on the hub one or two bolt positions from the original position. If the lateral runout cannot be corrected by indexing the rotor, check the hub and bearing assembly for excessive lateral runout or looseness. If the hub and bearing assembly lateral runout exceeds 0.040 mm (0.0015 in), replace the hub and bearing assembly. If lateral runout is within specifications, then refinish or replace the rotor as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Lateral Runout Check > Page 7074 Brake Rotor/Disc: Testing and Inspection Brake Rotor Thickness Variation Check Check the thickness variation by measuring the rotor thickness at four or more points around the circumference of the rotor. Use a micrometer calibrated in ten-thousands of an inch. Make all measurements at the same distance in from the edge of the rotor. A rotor that varies in thickness by more than 0.013 mm (0.0005 in) may cause a pedal pulsation and/or a front end vibration during the brake applications. A rotor that does not meet these specifications should be refinished to the specifications or replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Rotor Lateral Runout Check > Page 7075 Brake Rotor/Disc: Testing and Inspection Brake Rotor Tolerance In manufacturing the brake rotor, tolerances of the braking surfaces for flatness, parallelism and lateral runout are closely held. The maintenance of close tolerances on the shape of the braking surfaces is necessary in order to prevent brake roughness or pulsation. In addition to these tolerances, the surface finish must be held to a specific range. This range is 60 Ra roughness or less. The control of the braking surface finish is necessary in order to avoid problems of hard pedal apply, excessive brake fade, pulls and erratic performance. Control of the surface finish may improve the lining life. Light scoring of the rotor surfaces not exceeding 1.5 mm (0.06 inch) in depth, which may result from normal use, is not detrimental to brake operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement (Brake Rotor) Brake Rotor/Disc: Service and Repair Brake Rotor Replacement (Brake Rotor) Do not refinish the surfaces of new brake rotors. New rotors are at the correct level of finish surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement (Brake Rotor) > Page 7078 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement (Rotor Replacement) REMOVAL PROCEDURE 1. Raise vehicle 2. Remove front tires. Refer to Wheel Removal. 3. Remove brake caliper. Refer to Brake Caliper Replacement. 4. Remove brake rotor. INSTALLATION PROCEDURE 1. Install brake rotor. 2. Install brake caliper. Refer to Brake Caliper Replacement. 3. Install front tires. Refer to Wheel Installation. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: Customer Interest Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: All Technical Service Bulletins Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 7093 Backing Plate: Service and Repair REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the brake drum. Refer to Brake Drum Replacement. 3. Remove the inlet tube. 4. Remove the bolts (8) from the wheel cylinder. 5. Remove the parking brake cable from the backing plate. 6. Remove the hub and bearing assembly bolts. Refer to Rear Wheel Hub and Bearing Replacement. 7. Remove the backing plate (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 7094 NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the bolts (8) to the wheel cylinder. ^ Tighten the wheel cylinder bolts to 20 Nm (15 ft. lbs.). 2. Install the backing plate (1) to the axle assembly. 3. Install the hub and bearing assembly with bolts. Refer to Wheel Hub and Bearing Replacement. 4. Install the parking brake cable to the backing plate. 5. Install the inlet tube. ^ Tighten the tube nut to 23 Nm (17 ft. lbs.). 6. Install the brake components. Refer to Brake Drum Replacement. CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne If dust Is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. 7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding 8. Lower the vehicle. 9. Adjust the rear brake assembly. Refer to Brake Drum Replacement. 10. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Inside Diameter 7.874-7.890 in Runout 0.0006 in Maximum Re-Bore Diameter 7.899 in Discard Diameter 7.929 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7098 Brake Drum: Testing and Inspection Servicing the front brakes will usually correct pulsation in the brake pedal. Service the rear brakes only if the problem persists. In order to determine if the front or rear brakes are at fault, drive the vehicle at low speed in an area away from people and moving traffic (such as a large parking lot). Apply the parking brake and feel for the pulsation. If a pulsation is not noticed, the fault is probably in the front brakes. When the brake drums are removed, thoroughly clean and inspect the drums for the following conditions: ^ Cracks ^ Scores ^ Deep grooves ^ Out-of-round ^ Taper Normal, light scoring of brake drum surfaces not exceeding 1.2 mm (0.050 in.) in depth will not affect brake operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement REMOVAL PROCEDURE Tools Required ^ J 8049 Brake Spring Remover and Installer ^ J 29840 Brake Spring Remover and Installer ^ J 8057 Brake Spring Pliers 1. Raise and support the vehicle. Lifting and Jacking in General Information. Important: ^ Mark the relationship of the wheel to the axle flange in order to ensure proper wheel balance upon assembly. ^ Mark the relationship of the brake drum to the axle flange in order to ensure proper wheel balance upon assembly. 2. Remove the tire and wheel assembly. Refer to Wheel Removal. 3. Remove the brake drum. If removing the brake drum is difficult, refer to the following steps: ^ Ensure that the parking brake is released. ^ Back off the parking brake adjustment cable. ^ Use a rubber mallet in order to tap gently on the outer rim of the chum and/or around the inner drum diameter by the spindle. Do not use excessive force, which may deform the drum. 4. Remove the return springs (26, 27) using J 8049 or J 29840. 5. Remove the hold-down springs (22) and pins (10) using suitable pliers. 6. Remove the actuator link (28) while lifting up on the actuator lever (19). 7. Remove the actuator lever (19), the lever return spring (20), and the bearing sleeve (18). 8. Remove the parking brake strut (5) and the strut spring (4). 9. Disconnect the parking brake cable and remove the shoe and lining assemblies (29, 17). 10. Remove the adjusting screw assembly (21, 23, 24). 11. Remove the retaining ring (15), the pin (30), and the parking brake lever (16) from the secondary shoe (17). If any parts are of doubtful strength or quality due to discoloration from heat, overstress, or wear, replace the parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7101 CLEANING AND INSPECTION PROCEDURE 1. Before reinstalling the adjusting screw assembly (21, 23, 24), disassemble, clean and lubricate the component parts. 2. Clean the threads on the adjusting screw (23) with a wire brush. 3. Wash all components in clean denatured alcohol. 4. Apply brake lubricant or equivalent to the threads of the adjusting screw (23), the inside diameter of the socket (21), and the socket face. You have obtained an adequate supply of lubricant when a continuous bead of lubricant appears at the open end of the pivot nut (24) and the socket (21) after you have fully engaged the threads. 5. Lubricate the six pads (12) where the brake shoes contact the backing plate. 6. Inspect the threads of the adjusting screw (23) for smooth rotation over its full length. INSTALLATION PROCEDURE 1. Install the parking brake lever (16) into the secondary shoe (17) with the pin (30) and the retaining ring (15). 2. Install the adjusting screw assembly (1, 2, 3) and the adjusting screw spring (4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7102 3. Attach the parking brake cable. Install the shoe and lining assemblies (17, 29). 4. Install the parking brake strut (5) and the strut spring (4), by spreading the shoes (17, 29) apart. Verify that the shoes are positioned correctly: ^ The end without the strut spring (4) should engage the parking brake lever (16) and the secondary shoe and lining (17) ^ The end with the strut spring (4) should engage the primary shoe and lining (29) IMPORTANT: You must install the bearing sleeve (18) between the secondary shoe and lining (17) and the actuator lever (19). 5. Install the bearing sleeve (18), the actuator lever (19), and the lever return spring (20). 6. Install the hold-down pins (10) and the hold-down springs (22). 7. Install the actuator link (28) on the anchor pin (19) while you hold up on the lever. 8. Install the shoe return springs (26, 27) using J 8057. 9. Adjust the brakes. Refer to Drum Brake Adjustment. 10. Install the brake drum. Align the previous marks. 11. Install the tire and wheel assembly. Refer to Wheel Installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7103 12. Lower the vehicle. 13. Tighten the wheel nuts to specified torque. Refer to Fastener Tightening Specifications. 14. Adjust the parking brake. Refer to Park Brake Cable Service Adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7104 Brake Drum: Service and Repair Brake Drum Refinishing (Drum Refinishing) Remove only enough metal to obtain a true, smooth braking surface. A drum that does not clean-up when refinished to a maximum re-bore diameter, replace it. Removal of more metal will affect heat dissipation and may cause drum distortion. All brake drums have a maximum diameter cast into them. This diameter is the maximum wear diameter and not a finish diameter. When refinishing a brake drum, resurface the drum to no more than a dimension of 0.76 mm (0.030 in) less than the discard diameter. The refinish diameter is the maximum diameter. The brake drum may be refinished to and still allow safe braking action. If this dimension is exceeded, the brake drum will wear beyond the discard diameter during normal brake wear. Always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will vibration dampening attachments when refinishing brake surfaces. These attachments eliminate tool chatter so a better finish can be obtained. The optimum speed for refinishing braking surfaces is a spindle speed of 150 RPM. Crossfeed for rough cutting should range from 0.15-0.25 mm (0.006-0.010 in) per revolution. Finish cuts should be made at crossfeeds no greater than 0.05 mm (0.002 in) per revolution. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7105 Brake Drum: Service and Repair Brake Drum Refinishing (Refinish Procedure) Pulsation in the brake pedal is usually corrected by servicing the front brakes. Service the rear brakes only if the problem persists. To determine whether the front or rear brakes are at fault use the following test. Test Procedure 1. Drive the vehicle at a low speed in an area away from people and moving traffic, such as a large parking lot. 2. Apply the parking brake. 3. Feel for a pulsation. If a pulsation is not noticed the problem is most likely in the front brakes. Inspect Procedure 1. Remove the brake drums. 2. Thoroughly clean the brake drums. 3. Inspect the brake drums for cracks, scores, deep grooves, out-of-round and taper A normal, light scoring of the brake drum surfaces not exceeding 1.2 mm (0.050 in) in depth will not affect the brake operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7106 Brake Drum: Service and Repair Brake Drum Refinishing (Out of Round or Tapered Drums) An out-of-round or tapered drum prevents accurate brake shoe adjustment and is likely to cause excessive wear of other brake parts due to its eccentric action. An out-of-round drum can cause severe and irregular tire tread wear as well as a pulsating brake pedal. When the drum exceeds the specification limits in taper and/or out-of-round, refinish the drum to true up the braking surface. Out-of-round, as well as taper and wear, can be accurately measured with an inside micrometer and extension rods. When measuring the drum for out-of-round, taper and wear, take measurements at the open and closed edges of the machined surface and at right angles to each other. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Replace the rear brake shoes when the thickness is worn to within 0.76 mm (0.030 in) of the shoe or rivet head. Always replace the rear brake shoes as a complete axle set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 7110 Brake Shoe: Testing and Inspection Inspect the rear brake shoes every 6,000 miles and any time the wheels are removed (tire rotation, etc.). Inspect the rear brake shoes for wear by removing the rear brake drum. Replace the rear brake shoes when the thickness is worn to within 0.76 mm (0.030 in) of the shoe or rivet head. Always replace the rear brake shoes as a complete axle set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 7111 Brake Shoe: Service and Repair REMOVAL PROCEDURE Tools Required ^ J 8049 Brake Spring Remover and Installer, or ^ J 29840 Brake Spring Remover and Installer. ^ J 8057 Brake Spring Pliers. 1. Remove the return springs (1) using the J 8049 Brake Spring Remover and Installer, or the J 29840 Brake Spring Remover and Installer. 2. Remove the hold-down springs (1) and pins (3) using suitable pliers. 3. Remove the actuator link while lifting up on the actuator lever. 4. Remove the bearing sleeve. 5. Remove the actuator lever (19) and the lever return spring(20). 6. Remove the parking brake strut (5) and the strut spring(4). 7. Remove the shoe and lining assemblies (17 and 29) after disconnecting the parking brake cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 7112 8. Remove the adjusting screw assembly and the adjusting screw spring. 9. Remove the retaining ring, the pin and the parking brake lever from the secondary shoe. If any parts are of doubtful strength or quality due to discoloration from heat, over-stress, or worn, the parts should be replaced. INSTALLATION PROCEDURE 1. Install the parking brake lever on the secondary shoe with the pin and the retaining ring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 7113 2. Install the adjusting screw assembly and the adjusting screw spring. Before reinstalling the adjusting screw assembly, it must be disassembled, thoroughly cleaned and lubricated, as follows: ^ Clean the adjusting screw threads with a wire brush. ^ Wash all the components in clean, denatured alcohol. ^ Apply brake lubricant or equivalent to the adjusting screw threads, inside diameter of the socket and socket face. Adequate lubrication is achieved when a continuous bead of lubricant is at the open end of the pivot nut and socket, when the threads are fully engaged. ^ Lubricate the six pads on the backing plate where the backing plate makes contact with the brake shoes. ^ Inspect the threads of the adjusting screw for smooth rotation over full length. 3. Install the shoe and lining assemblies, after attaching the parking brake cable. 4. Install the parking brake strut and strut spring by spreading the shoes apart. To be properly positioned: ^ The end without the strut spring should engage the parking brake lever and the secondary shoe and lining. ^ The end with the strut spring should engage the primary shoe and lining. Important: The bearing sleeve must be installed between the secondary shoe and lining and the actuator lever. 5. Install the bearing sleeve, the actuator lever and the lever return spring. 6. Install the hold-down pins and the hold-down springs. 7. Install the actuator link on the anchor pin. 8. Install the actuator link into the actuator lever while holding up on the lever. 9. Install the shoe return springs, using the J 8057 Brake Spring Pliers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7118 Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62 in.lb Wheel Cylinder to Backing Plate 15 ft.lb Inlet Tube Nut 17 ft.lb Wheel Cylinder Bore Diameter 0.689 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement Wheel Cylinder: Service and Repair Wheel Cylinder Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. 2. Clean any dirt or foreign material around the wheel cylinder assembly inlet and pilot. 3. Remove the inlet tube nut and line. Plug the opening in the line to prevent fluid loss and contamination. 4. Remove the brake drum. Refer to Brake Drum Replacement. 5. Remove the hub and bearing assembly. Refer to Rear Wheel Hub and Bearing Replacement. 6. Pull the backing plate (1) away from the axle flange. Do not let the backing plate hang from the parking brake cable as damage may occur. Refer to Drum Brake Backing Plate Replacement. 7. Remove the wheel cylinder bolts using a #6 Torch socket. 8. Remove the wheel cylinder (14). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7121 INSTALLATION PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the wheel cylinder bolts (8) using a #6 Torx socket. ^ Tighten the wheel cylinder bolts to 20 Nm (15 ft. lbs.). 2. Install the backing plate (11) to the axle flange. 3. Install the hub and bearing assembly. Refer to Rear Wheel Hub and Bearing Replacement. 4. Install the brake drum. Refer to Brake Drum Replacement. 5. Install the inlet tube line and nut. ^ Tighten the inlet tube nut to 23 Nm (17 ft. lbs.). CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. 6. Bleed the wheel cylinder and then the complete brake system. Refer to Brake Bleeding. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7122 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY PROCEDURE 1. Remove the wheel cylinder from the vehicle. Refer to Wheel Cylinder Replacement. 2. Remove the wheel cylinder boots (4). 3. Remove the wheel cylinder pistons (3) and seals (2). 4. Remove the wheel cylinder spring assembly (5). 5. Remove the wheel cylinder bleeder valve (6). 6. Inspect the cylinder bore (1) and pistons (3) for scoring, nicks, corrosion and wear. Use a crocus cloth in order to polish out light corrosion. Replace the wheel cylinder assembly if the bore will not clean up using the crocus cloth. 7. Clean all the parts in clean, denatured alcohol. 8. Dry the parts with unlubricated, compressed air. CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne If dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. Notice: Brake fluid will damage painted surfaces. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 9. Lubricate the new seals (2) with clean brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7123 ASSEMBLY PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the bleeder valve (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 2. Install the spring assembly (5). 3. Install the seals (2), pistons (3) and boots (4). 4. Install the wheel cylinder to the vehicle. Refer to Wheel Cylinder Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure Brake Bleeding: Service and Repair Motor Rehome Procedure REHOME TEST The motor rehome function will return all of the hydraulic modulator pistons to their upmost home, position. This allows all fluid paths within the modulator to be open so that the modulator can be properly bled. The motor rehome function must ALWAYS be used prior to bleeding the brake system IMPORTANT: The motor rehome function cannot be performed if any current DTCs are present. If current DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 7129 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding CAUTION: Do not move the vehicle until a firm brake pedal is obtained. Air In the brake system can cause the loss of brakes with possible personal injury. A bleeding operation is necessary in order to remove air from the hydraulic brake system whenever air is introduced into the brake system. Bleed the hydraulic system at all four brakes if air has been introduced into the system through low fluid level or by disconnecting the brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, bleed only that wheel cylinder/caliper. If the pipes are disconnected at any fitting located between the master cylinder and brakes, bleed the brake system served by the disconnected pipe. Observe the following steps in order to reduce the time required to bleed the hydraulic system: ^ Ensure that the master cylinder reservoir is filled with brake fluid. ^ Expel as much air as possible before installing the master cylinder on the vehicle. MANUAL BLEEDING Tools Required ^ J 21472 Brake Bleeder Wrench Apply the brakes several times with the ignition OFF. This will deplete the vacuum reserve. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with the specified brake fluid in Maintenance and Lubrication in General Information. ^ Maintain the fluid level in the reservoir during the bleeding operation. ^ Use an assistant in the vehicle in order to press the brake pedal during the manual bleeding process. 2. If the master cylinder is known or suspected to have air in the bore, bleed the master cylinder before the wheel cylinder or the calipers are bled. Complete the following steps: 3. Disconnect the forward brake pipe connections) (1) at the master cylinder. 4. Fill the master cylinder with brake fluid until fluid begins to flow from the forward pipe connector port. 5. Connect the forward brake pipe to the master cylinder. Tighten the pipe. 6. Slowly depress the brake pedal and hold the pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 7130 7. Loosen the forward brake pipe connection at the master cylinder in order to purge air from the cylinder. 8. Tighten the connection. 9. Slowly release the brake pedal. 10. Wait 15 seconds. 11. Repeat the previous eight steps until all air is removed from the bore. Use extreme care in order to prevent brake fluid from contacting painted surfaces. 12. Bleed the master cylinder at the rear (cowl end) connections after all the air has been removed at the forward connections. Slowly depress the brake pedal and hold the pedal. 13. Check for a firm pedal feel and proper brake pedal travel. If the wheel cylinders and calipers do not contain air, bleeding is not necessary, but recommended in order to remove any moisture or debris. 14. After all air is removed from the master cylinder, bleed the wheel cylinders in the following order, if necessary: 14.1. Right rear 14.2. Left rear 14.3. Right front 14.4. Left front 15. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 16. Place a proper size box end wrench (1) (or special tool) over the caliper/cylinder bleeder valve. 17. Attach a transparent tube (2) over the bleeder screw. Submerge the other end in a transparent container partially filled with clean brake fluid. 18. Slowly depress the brake pedal and hold the pedal. 19. Loosen the bleeder screw in order to purge the air from the cylinder/caliper. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 20. Tighten the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (62 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm (115 inch lbs.). 21. Slowly release the pedal. 22. Wait 15 seconds. 23. Repeat the previous five steps until all air is removed from the caliper. Do not pump the brake pedal rapidly. Pumping the pedal pushes the master cylinder secondary piston down the bore which causes difficult bleeding. 24. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 7131 25. Fill the master cylinder to the proper level. 26. Check the brake pedal for sponginess or excessive travel. Repeat the entire manual bleeding procedure in order to correct either of the two conditions. PRESSURE BLEEDING Tools Required ^ J 29532 Diaphragm Type Brake Bleeder ^ J 35589 pressure Bleeder Adapter Cap ^ J 21472 Brake Bleeder Wrench NOTICE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install the J 35589 to the master cylinder 2. Charge the J 29532 to 140-172 kPa (20-25 psi). 3. Connect the line to the J 35589. 4. Open the line valve. 5. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking. 6. Bleed the wheel cylinders/calipers in the following order, if necessary: 6.1. Right rear 6.2. Left rear 6.3. Right front 6.4. Left front 7. Place the J 21472 over the caliper/cylinder bleeder valve. 8. Attach a transparent tube over the bleeder screw. Submerge the opposite hose end in a transparent container partially filled with clean brake fluid. 9. Open the bleeder screw at least 3/4 of a turn. Allow the fluid to flow until no air is visible in the fluid. 10. Close the bleeder screw. ^ Tighten the rear bleeder screws to 7 Nm (6.2 inch lbs.). ^ Tighten the front bleeder screws to 13 Nm ( 115 inch lbs.). 11. Repeat the previous four steps until all of the calipers/cylinders have been bled. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Motor Rehome Procedure > Page 7132 12. Lower the vehicle. 13. Inspect the brake pedal for sponginess. Repeat this entire pressure bleeding procedure in order to correct this conditions. 14. Remove the J 35589 and the J 29532. 15. Fill the master cylinder to the proper level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Bleeder Screws 115 in.lb Caliper Inlet Fitting 34 ft.lb Caliper Mounting Bolts 38 ft.lb Caliper Bore Diameter 2.244 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement Brake Caliper: Service and Repair Brake Caliper Replacement REMOVAL PROCEDURE 1. Remove 2/3 of the brake fluid from the master cylinder assembly. 2. Raise the vehicle and suitably support the vehicle. 3. Mark the relationship of the wheel to the hub and bearing assembly in order to ensure proper wheel balance upon reassembly. 4. Remove the tire and wheel assembly. Refer to Wheel Removal. Reinstall two wheel nuts in order to retain the rotor to hub and bearing assembly. 5. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor. 6. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough in order to slide the caliper assembly off the rotor. 7. Remove the bolt attaching inlet fitting (5) only when the caliper (2) is to be removed from the vehicle for unit repair (overhaul). If only the shoe and linings are being replaced, there is no need to disconnect the inlet fitting (5). Plug the exposed inlet fitting (5) in the caliper housing and the brake hose to prevent fluid loss and contamination. 8. Remove the caliper mounting bolts (1) and sleeve assemblies. 9. Remove the caliper from the rotor and knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7138 ^ Do not let the caliper (2) hang from the brake hose. Damage may occur. ^ If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut (1). 10. Inspect the mounting bolts (1) and sleeve (4) assemblies for corrosion. 11. Inspect the bushings (2) for cuts and nicks. 12. If damage to either part is found, replace with new parts when installing the caliper. 13. Do no attempt to polish away corrosion. INSTALLATION PROCEDURE 1. Liberally coat the inside of the diameter of the bushings (4) with silicone grease (4). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the mounting bolts (1) and sleeve (4) assemblies (1). 3. Install the caliper (2) over the rotor into the knuckle. ^ Tighten the mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7139 4. Install the inlet fitting, if the inlet fitting was removed. ^ Tighten the inlet fitting to 44 Nm (32 ft. lbs.). 5. Perform the following steps in order to install the wheel and tire, aligning the previous marks: 5.1. Remove the wheel nuts securing the rotor to the hub and bearing assembly. 5.2. Install the wheel and tire assembly with the retaining nuts in the proper sequence. Refer to Wheel Installation. 5.3. Lower the vehicle. 5.4. Tighten the wheel nuts. Refer to Wheel Fastner Specifications. 6. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 6.1. Bleed the caliper if the inlet fitting was removed. Refer to Brake Bleeding in Hydraulic Brakes. 6.2. Recheck the fluid level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 6.3. Recheck the brake pedal feel. If brake spongyness is present, refer to Brake System Testing and Inspection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7140 Brake Caliper: Service and Repair Brake Caliper Overhaul REMOVAL PROCEDURE 1. Remove the caliper completely from the vehicle. Refer to Brake Caliper Replacement. 2. Disassemble the bushings (6). 3. Inspect the bushings (6) for cuts and nicks. Replace the bushings (6) if damaged. CAUTION: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. IMPORTANT: Use clean shop towels in order to pad the interior of the caliper housing during the removal. 4. Remove the piston using compressed air into the caliper inlet hole (1). 5. Inspect the piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace the piston if any of these conditions are found. 6. Remove the boot (2) from the caliper housing bore. Be careful not to scratch the housing bore. Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result. 7. Remove the piston seal grove in the caliper housing bore with a small wood or plastic tool. 8. Inspect the caliper housing bore and seal groove for scoring, nicks, corrosion and wear. 9. Use a crocus cloth to polish out light corrosion. 10. Replace the caliper (1) housing if corrosion in and around the seal groove will not clean up with a crocus cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7141 11. Remove the bleeder valve and bleeder valve (5) cap from the caliper. 12. Clean all parts in clean, denatured alcohol. 13. Dry the parts with unlubricated compressed air. 14. Blow out all passages in the caliper housing and bleeder valve. INSTALLATION PROCEDURE Tools Required ^ J29077-A Front Disc Brake Caliper Dust Boot Installer NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Assemble the bleeder valve (5) and bleeder valve cap into caliper. ^ Tighten the bleeder valve to 13 Nm (115 inch lbs.). 2. Lubricate the new piston seal (2) and install the new piston seal into the caliper bore groove. 3. Make sure the seal (2) is not twisted. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement > Page 7142 4. Install the lubricated boot (2) onto the piston (1). 5. Install the piston and boot onto the bore of the caliper and push to the bottom of the bore. 6. Seat boot fin the caliper housing counter bore using J29077-A. 7. Perform the following steps in order to install the bushings: 7.1. Lubricate the beveled end of the bushing with silicone grease, or the equivalent. 7.2. Pinch the bushing and install the bevel end first. 7.3. Push the bushing through the housing mounting bore. 8. Install the caliper. Refer to Brake Caliper Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 7147 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 7148 Brake Fluid: Specifications Brake System DOT 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Brake Fluid Brake Fluid: Service Precautions Brake Fluid CAUTION: Brake fluid may Irritate eyes and skin. In case of contact, take the following actions: ^ Eye contact-rinse thoroughly with water. ^ Skin contact-wash with soap and water. ^ If Ingested-consult a physician Immediately. NOTICE: Brake fluid is extremely damaging to paint. If fluid should accidentally touch a painted surface, immediately wipe fluid from paint and clean the painted surface. Use Delco Supreme II Brake Fluid or an equivalent DOT-3 motor vehicle brake fluid. DOT-5 silicone fluid is not recommended for use in the vehicle's base brake system. DO NOT use DOT-5 brake fluid in the antilock brake system. Always store the brake fluid in a closed container. Reseal brake fluid containers immediately after use. Brake fluid that is left in an open or improperly sealed container will absorb moisture. This may lower the fluid's boiling point and may result in system contamination, corrosion or deterioration of the rubber components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Brake Fluid > Page 7151 Brake Fluid: Service Precautions Substandard Brake Fluid NOTICE: Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone brake fluid. Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components to deteriorate. Keep all fluid containers capped to prevent contamination. IMPORTANT: Improper brake fluid such as, mineral oil or water in the fluid, may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate. Upon inspection, if the primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evidenced by the swollen wheel cylinder piston cups on the drum brake wheel cylinders or the master cylinder cover diaphragm. If deterioration of rubber parts is evident disassemble all hydraulic parts and was with alcohol. Dry these parts with unlubricated compressed air before assembly to keep alcohol out of the system. Replace all rubber parts when in the system, including hoses. Also, when working on the brake mechanisms, check for fluid on the brake linings. If any fluid is found, replace the linings. If the master cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If excessive heat conditions are not found, drain the fluid. Flush, the system with brake fluid. Refill and bleed the system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Switch Location Left hand rear of engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 7156 Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Indicator, ABS Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 7157 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7158 Brake Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7159 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector from the fluid level switch (1). 2. Disconnect the fluid level switch using needle nose pliers in order to compress the switch locking tabs (1) at the inboard side of the master cylinder. INSTALLATION PROCEDURE 1. Connect the fluid level switch into the master cylinder reservoir until the locking tabs (3) snap into place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7160 2. Connect the electrical connector to the fluid level switch (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > NHTSA00V053000 > Feb > 00 > Recall 00V053000: CNG Fuel and/or Brake System Leak Brake Hose/Line: Recalls Recall 00V053000: CNG Fuel and/or Brake System Leak Vehicle Description: Passenger vehicles equipped with Bi-Fuel Compressed Natural Gas (CNG) vehicles. The CNG fuel line and the CNG high pressure regulator coolant lines can contact other fuel (gasoline) and brake lines on the vehicle. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. A brake fluid leak could disable a portion of the brake system, causing longer stopping distances. Gasoline leaking from a fuel pipe, in the presence of an ignition source, could cause a vehicle fire. Dealers will inspect and reposition the CNG fuel and coolant pipes and reposition/repair any damaged fuel or brake pipes as necessary. Owner notification began March 17, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > NHTSA00V053000 > Feb > 00 > Recall 00V053000: CNG Fuel and/or Brake System Leak Brake Hose/Line: All Technical Service Bulletins Recall 00V053000: CNG Fuel and/or Brake System Leak Vehicle Description: Passenger vehicles equipped with Bi-Fuel Compressed Natural Gas (CNG) vehicles. The CNG fuel line and the CNG high pressure regulator coolant lines can contact other fuel (gasoline) and brake lines on the vehicle. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. Abrasion from contact can cause a leak in the brake pipe, fuel pipe, or both. A brake fluid leak could disable a portion of the brake system, causing longer stopping distances. Gasoline leaking from a fuel pipe, in the presence of an ignition source, could cause a vehicle fire. Dealers will inspect and reposition the CNG fuel and coolant pipes and reposition/repair any damaged fuel or brake pipes as necessary. Owner notification began March 17, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Line Brake Hose/Line: Specifications Brake Line Brake Pipe Tube Nuts ......................................................................................................................... ..................................................... 23 N.m (17 ft. lbs.) Brake Pipes at Master Cylinder ...................... ......................................................................................................................................... 23 N.m (17 ft. lbs.) Brake Line Bracket to Axle Screw .......................................................................................................................................................... 15 N.m (11 ft. lbs.) Brake Line Bracket to Body Screw ...................................................................................................................................................... 11 N.m (97 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Line > Page 7176 Brake Hose/Line: Specifications Brake Hose Brake Hose to Caliper ......................................................................................................................... .................................................... 44 N.m (32 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7177 Brake Hose/Line: Service Precautions Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7178 Brake Hose/Line: Testing and Inspection IMPORTANT: Do not allow brake components such as the calipers to hang from the flexible hoses. This can damage the hoses. Brake hoses may have protective rings or covers. This is to prevent direct contact direct contact of the hose with other chassis parts. Other than the possible structural damage, excessive tension can also cause the hose rings to move out of place. ^ Inspect the hydraulic brake hoses (1) at least twice a year. ^ Inspect the brake hose assemblies (5) for the following conditions: - Road hazard damage Cracks and chafing of the outer cover - Leaks and blisters - Proper routing and mounting ^ If any of the above conditions are found, adjust or replace the hose assembly. A brake hose which rubs on other components will wear and eventually fail. ^ Use a light and a mirror in order to thoroughly inspect the hose assemblies. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7179 Brake Hose/Line: Service and Repair Tools Required J29803-A ISO Flaring Kit NOTICE: Do not use a single lap flaring tools. Double lap flaring tools must be used to produce a flare strong enough to hold the system pressure. Using lap single flaring tools could cause system damage. 1. Obtain the recommended pipe and steel fitting nuts of the correct size. Use the outside diameter of the pipe in order to specify the size. 2. Cut the pipe to the correct length using a pipe cutter. Advance the tool only a small amount per turn of the tool. Do not force the cutter. 3. Measure the old pipe in order to determine the correct length of the pipe. Use a string in order to measure, and add 3.2 mm (1/8 inch) for each ISO flare. 4. Install the fittings before starting the flare. 5. Chamfer the inside and the outside diameter of the pipe using a de-burring tool. 6. Remove all traces of lubricant from the brake pipe and the J 29803-A. 7. Clamp the J29803-A in a vise. 8. Select the correct size collet (2) and forming mandrel for the pipe size used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7180 9. Insert the properly formed mandrel (3) into the J 29803-A. 10. Hold the forming mandrel (3) in place using your finger. 11. Thread in the forcing screw (2) until contact is made and the screw begins to move the forming mandrel (3). 12. Turn the forcing screw back one complete turn. 13. Slide the clamping nut over the brake pipe. 14. insert the prepared brake pipe into the correct collet (2). Leave approximately 19 mm (0.750 in) of tubing extending out of the collet. Insert the assembly into the J 29803-A. Ensure that the brake pipe end contacts the face of the forming mandrel. 15. Tighten the clamping nut (1) into the J29803-A body tightly in order to ensure that the pipe will not push out. 16. Wrench tighten the forcing screw until the screw bottoms. Do not over tighten the forcing screw or the flare may become oversized. 17. Back the clamping nut (1) out of the J 29803-A. 18. Disassemble the clamping nut (1) and the collet assembly. 19. The flare is now ready for use. 20. Bend the pipe assembly to match the old pipe. 21. Maintain a clearance of 19 mm (0.0750 in) to all moving or vibrating parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Proportioning Valve Caps .................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7184 Brake Proportioning/Combination Valve: Service and Repair REMOVAL PROCEDURE CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne If dust Is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 1. Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement. 2. Remove the proportioner valve caps (1). 3. Remove the proportioner valve cap O-rings. Discard the O-rings (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7185 4. Remove the proportioner valve piston springs (1) 5. Remove the proportioner valve pistons using needle nose pliers. Do not scratch or damage the piston stems (1). 6. Remove the proportioner valve seals (1) from the proportioner valve pistons. 7. Clean all parts with denatured alcohol. 8. Dry all parts using non-lubricated compressed air. 9. Inspect the proportioner valve pistons for corrosion or deformation. 10. Replace the parts if defects are found. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7186 INSTALLATION PROCEDURE 1. Lubricate the new proportioner valve cap O-rings (5) and proportioner valve seals (4) with silicone grease that is supplied in the repair kit. 2. Lubricate the stem of the proportioner valve pistons (1). 3. Connect the new proportioner valve seals (1) on the proportioner valve pistons. Install the proportioner valve pistons with the seal lips facing upward toward the proportioner valve cap. 4. Install the proportioner valve pistons (1) and seals in the master cylinder body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7187 5. Install the proportioner valve piston springs (1) in the master cylinder body. 6. Connect the new proportioner valve cap O-rings (1) in the grooves in the proportioner valve caps. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 7. Install the proportioner valve caps (1) in the master cylinder body. ^ Tighten the proportioner valve caps to 27 Nm (20 ft. lbs.). 8. Install the master cylinder reservoir if removed. Refer to Master Cylinder Reservoir Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Specifications Hydraulic Assembly: Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7193 Hydraulic Assembly: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7194 LF And RF ABS Solenoid And ABS Actuator Motor Assembly Connectors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7195 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7196 Brake Fluid Level Indicator And Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7197 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Page 7198 Hydraulic Assembly: Diagrams LF ABS Solenoid RF ABS Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement Hydraulic Assembly: Service and Repair ABS Motor Pack Replacement REMOVAL PROCEDURE 1. Remove the gear cover (3). Important: ^ Use care when handling the motor pack to avoid damaging the motor pack connector. Make sure brake fluid does not accidentally intrude into the motor pack. Brake fluid in the motor pack may cause a premature failure of the motor pack. ^ Use care when handling the motor packs. Replace the motor packs if the motor packs are dropped or damages during handling. 2. Remove the Torx head screws (5) that attach the motor pack (1). 3. Remove the motor pack assembly (1). Important: If the disassembly of the modulator/master cylinder assembly was caused by an ABS or ETS hydraulic functional test that did not pass, the Automated ABS brake motor pack Diagnosis Test should be performed. Refer to Scan Tool diagnostics in Antilock Brake System. The Automated ABS brake motor pack Diagnosis Test isolates the motor pack or brake modulator. No repair of the motor pack is authorized. Replace as an assembly. INSTALLATION PROCEDURE 1. With the modulator positioned upside down, rotate each ABS brake modulator gear counterclockwise until movement stops. The above procedure will cause the following conditions: ^ The pistons on the ABS brake modulator will be positioned very close to the top of the modulator bore. ^ The brake bleeding procedure becomes simplified. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7201 IMPORTANT: Use care when handling the motor packs. Replace the motor packs if the motor packs are dropped or damaged during handling. Align each of the three motor pack pinions with the modulator gears. 2. Install the motor pack (1) to the modulator assembly (6). 3. Install Torx head screws (4). ^ Tighten the Torx head screws to 4.5 Nm (40 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the gear cover (3) onto the modulator/brake master cylinder assembly. 5. Perform Motor Rehome Procedure. 6. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7202 Hydraulic Assembly: Service and Repair Brake Modulator Gear Replacement REMOVAL PROCEDURE CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing brake modulator drive gear cover, exercise extreme care not to place fingers intor the gear set, since fingers can be pinched by rotating gears. NOTICE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. IMPORTANT: Do not repair damaged motor packs or brake modulators. Other than modulator drive gears replacement, repair of the motor pack and brake modulator assemblies is not authorized. Do not oil or lubricate the gears on the motor pack. 1. Remove the brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly. 2. Remove the Torx head screws that attach the gear cover. 3. Remove the motor pack to modulator Torx head screws. Important: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling. 4. Separate the motor pack from the modulator. 5. Remove three modulator drive gear retaining nuts. 6. Remove the gears from the modulator. INSTALLATION PROCEDURE 1. Position the modulator drive gears onto the modulator drive shaft. Notice: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7203 2. Install three gear retaining nuts. ^ Tighten the nuts to 8.5 Nm (75 inch lbs.). 3. With either of the modulators positioned upside down, and the gears facing your, rotate each ABS brake modulator gear counterclockwise until movement stops. Rotating the modulator gears will cause the following conditions: ^ The pistons on the ABS brake modulator will be positioned very close to the top of the modulator bore. ^ The brake bleeding procedure is simplified. Important: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling. 4. Position the motor pack onto the modulator, aligning the three motor pack gears with the modulator gears. 5. Install motor pack to modulator Torx head screws. ^ Tighten the Torx head screws to 4.5 Nm (40 ft. lbs.). 6. Install the gear cover onto the modulator with Torx head screws. ^ Tighten the Torx head screws to 4 Nm (45 inch lbs.) 7. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly. 8. Perform the Motor Rehome Procedure. 9. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7204 Hydraulic Assembly: Service and Repair Brake Modulator Replacement REMOVAL PROCEDURE 1. Remove the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement. 2. Remove the Torx head screws (5) attaching the gear cover (4). 3. Remove the gear cover (4). 4. Remove the four Torx head screws (6) attaching the motor pack (1) to the brake modulator (2). 5. Remove the motor pack (1) from the brake modulator (2). 6. Remove the two brake modulator to master cylinder banjo bolts, separate the brake modulator from the master cylinder. 7. Remove the two transfer tubes with the O-rings from the master cylinder or the brake modulator. 8. Remove the banjo bolt O-rings from the master cylinder and the brake modulator. INSTALLATION PROCEDURE IMPORTANT: When replacing the ABS brake modulator, install the three gears in the same location on the replacement brake modulator. Refer to Brake Modulator Gear Replacement in Hydraulic Assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7205 No repair of the ABS brake modulator is authorized. Replace the ABS brake modulator as an assembly. IMPORTANT: Use new transfer tube assemblies when assembling the ABS brake modulator/master cylinder assembly. Be sure to properly install two O-rings on each transfer tube. 1. Use the following procedure in order to install the two transfer assemblies: 1.1. Lubricate the transfer tube assembly O-rings with clean brake fluid. 1.2. Install the transfer tube assemblies into ports of the ABS brake modulator. Push the tube assemblies in by hand to the bottom of the ports. 2. Lubricate the new banjo bolt 0-ring with clean brake fluid. 3. Install the banjo bolt 0-ring into the master cylinder and the ABS brake modulator. 4. Use the following procedure in order to install the ABS brake modulator onto the master cylinder: 4.1. Clamp the mounting flange of the master cylinder in a vise. 4.2. Hold the ABS brake modulator and rock the modulator into position on the master cylinder. 4.3. Insert the transfer tube assemblies into the master cylinder ports. 5. Install two ABS brake modulator to master cylinder banjo bolts. Tighten Tighten the banjo bolts to 24 Nm (18 ft. lbs.). 6. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until movement stops. The procedure causes the following conditions: ^ The pistons are positioned very close to the top of the modulator bore. ^ The brake bleeding procedure is simplified. 7. Install the ABS brake motor pack (1) onto the brake modulator/master cylinder assembly (2). 8. Install the four Torx head screws (6) that retain the motor pack (1) to the brake modulator (2). Tighten Tighten the four Torx head screws to 5 Nm (44 inch lbs.). 9. Install the gear cover (4) to the brake modulator/master cylinder assembly (2). 10. Install the Torx head screws (5) that retain the gear cover (4). Tighten Tighten the Torx head screws to 4 Nm (36 inch lbs.). 11. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement 12. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7206 Hydraulic Assembly: Service and Repair Modulator Gear Cover Replacement REMOVAL PROCEDURE 1. Remove the Torx head screws (4) that attach the gear cover (3). 2. Remove the gear cover (3). INSTALLATION PROCEDURE 1. Install the gear cover (3) onto the modulator/master cylinder assembly. 2. Install the Torx head screws (4). ^ Tighten the Torx screws to 4 Nm (36 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Service and Repair > ABS Motor Pack Replacement > Page 7207 other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7216 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7217 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7223 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7224 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Fastener Tightening Specifications Master Cylinder Assembly to Power Booster Nuts ............................................................................................................................. 27 N.m (20 ft. lbs.) Dimensions Master Cylinder Bore Diameter ..................................................................................................................................................... 22.20 mm (0.874 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7228 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7229 Brake Master Cylinder: Description and Operation IMPORTANT: ^ Install all new components included in the repair kit that are used in order to service the master cylinder. ^ Lubricate rubber parts with clean brake fluid in order to ease assembly. ^ Do not use lubricated compressed air on brake parts. Damage to rubber components may result. ^ If any hydraulic component is removed or disconnected, bleed all or part of the brake system. ^ The fastener tightening specifications are for dry, non-lubricated fasteners. ^ Perform service operations on a clean bench, free from all mineral oil materials. The master cylinder for this vehicle is a composite design which contains a plastic reservoir and an aluminum body. This design is used in a diagonally split system. One of the front and one of the diagonally opposite rear brakes are served by the primary piston. The opposite front and rear brakes are served by the secondary piston. The master cylinder incorporates the-functions of a standard dual master cylinder. The master cylinder has a fluid level switch and integral proportioner valves. The proportioner valves are designed in order to provide a better front to rear braking balance during a heavy brake application. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7230 Brake Master Cylinder: Testing and Inspection The following inspections determine all master cylinder malfunctions. If the problem is not found by using the following tests, refer to Brake System Diagnosis (General Diagnosis) in order to help isolate the problem. CAUTION: Brake fluid may Irritate eyes and skin. In case of contact, take the following action: ^ Eye contact-rinse thoroughly with water. ^ Skin contact-wash with soap and water. ^ If ingested-consult a physician immediately. NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, immediately flush the area with water to minimize the potential for damage. IMPORTANT: ^ Use only Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. ^ Do not use power steering or transmission fluid in the brake system. ^ Do not reuse brake fluid accumulated during the brake system bleeding. ^ Always store brake fluid in a closed container. Reseal brake fluid containers immediately after use. ^ Do not use brake fluid that was left in an open or improperly sealed container. The brake fluid will absorb moisture or may become contaminated. 1. Inspect for a cracked master cylinder casting. 2. Inspect for brake fluid around the master cylinder. A leak is present if there is at least one drop of fluid. A damp condition is not abnormal. 3. Inspect for a binding pedal linkage. 4. If the pedal linkage is correct, disassemble the master cylinder. Inspect for swollen or elongated primary piston seal(s). 5. If the seals are swollen, substandard or contaminated brake fluid is the probable cause. If the brake fluid is contaminated, use the following procedure: 5.1. Disassemble and clean the serviceable components. 5.2. Replace all of the rubber and non-serviceable components. 5.3. Flush all of the brake pipes and brake hoses. Refer to Hydraulic Brake System Flushing. Any of the following conditions may cause the brake fluid to boil: ^ Improper brake fluid ^ Improper brake fluid may also cause the rubber components to deteriorate. ^ Power steering fluid ^ Transmission fluid ^ Water in the brake fluid If the master cylinder cap diaphragm is swollen, then rubber parts have deteriorated. Deterioration may be evident by swollen wheel cylinder boots and caliper boots. If deterioration of the rubber parts is evident, complete the following steps: 1. Disassemble all serviceable hydraulic components. 2. Wash the components with alcohol. 3. Dry the parts with non-lubricated compressed air before assembly in order to keep alcohol out of the system. 4. Replace all rubber parts in the system, including hoses and non-serviceable hydraulic components. 5. Refill the master cylinder reservoir with new brake fluid. 6. Flush the brake system. Refer to Hydraulic Brake System Flushing. 7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) Brake Master Cylinder: Service and Repair Brake Modulator/Master Cylinder ASM Replacement (with ABS) REMOVAL PROCEDURE CAUTION: To help avoid personal injury, due to a retained load on the brake modulator, the Gear Tension Relief function of the scan tool must be performed prior to removal of the ABS brake modulator/master cylinder assembly. 1. Use the Scan fool in order to perform the Gear Tension Relief Sequence. 2. Disconnect two brake solenoid valve electrical connectors (1), (3). 3. Disconnect the brake fluid level indicator sensor connector (2). 4. Disconnect the ABS brake motor pack 6-way electrical connector (6). 5. Remove four brake pipes (5). 6. Remove the two nuts (8) attaching the ABS brake modulator/master cylinder assembly (7) to the vacuum booster. 7. Remove the ABS brake modulator/master cylinder assembly (7). INSTALLATION PROCEDURE 1. Install the ABS brake modulator/master cylinder assembly (7) into the vehicle. Install the two nuts (8) attaching the ABS modulator master cylinder assembly (7). ^ Tighten the ABS brake modulator/master cylinder nuts (8) to 27 Nm (20 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install four brake pipes (5) onto the ABS brake modulator/master cylinder assembly (7). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7233 ^ Tighten the tube nuts to 24 Nm (18 ft. lbs.). 3. Connect the ABS brake motor pack 6-way electrical connector (6). 4. Connect the brake fluid level indicator sensor electrical connector (2). 5. Connect two brake solenoid valve electrical connectors (1), (3). Important: Bleed the system. Refer to Bleeding Brake Hydraulic System in Brake Bleeding. 6. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7234 Brake Master Cylinder: Service and Repair Master Cylinder Cover/Caps Replacement (Reservoir Cap Cleaning) REMOVAL PROCEDURE 1. Clean the master cylinder reservoir cap (1) before removal to avoid dirt entering the reservoir. 2. Remove the reservoir cap (1). 3. Remove the rubber diaphragm from cap (2). 4. Clean any brake fluid that exists between the cap and the rubber diaphragm with a dry lint free rag. 5. Inspect the brake fluid for the proper level. Remove fluid if necessary. INSTALLATION PROCEDURE 1. Install the rubber diaphragm (1) into the reservoir cap (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7235 2. Install the reservoir cap (2) to the reservoir (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7236 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul DISASSEMBLY PROCEDURE IMPORTANT: The master cylinder reservoir cover and reservoir diaphragm may be inspected and/or serviced without removing the master cylinder from the vehicle. 1. Remove the master cylinder completely from the vehicle. Refer to Master Cylinder Replacement. 2. Separate the modulator assembly from the master cylinder assembly Refer to Brake Modulator/Master Cylinder Asm Replacement in Antilock Brake System Traction Control. 3. Clean the master cylinder reservoir cover. 4. Remove the master cylinder reservoir cover (1). 5. Remove the master cylinder reservoir diaphragm (2). 6. Empty the fluid from the reservoir. Empty the fluid only if the master cylinder is to be completely removed and overhauled. 7. Inspect the master cylinder cover and the diaphragm for the following conditions. Replace the parts as necessary: ^ Cuts ^ Cracks ^ Nicks ^ Deformation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7237 8. Remove the fluid level switch (1). 9. Remove the proportioner valve assemblies. 10. Remove the piston retainer (12) while depressing the primary piston. Do not damage the primary piston (11), the master cylinder bore or the piston retainer groove (18). 11. Remove the primary piston (11). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 12. Remove the secondary piston (9). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 13. Remove the secondary piston spring (6) and the spring retainer (7). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 14. Remove the secondary seal (10). 15. Remove the primary seal (8). 16. Remove the spring retainer from the secondary piston (9). ^ Clean all parts in clean denatured alcohol. ^ Dry the parts with non-lubricated compressed air. ^ Do not use an abrasive on the bore. 17. Inspect the master cylinder bore for scoring or corrosion. Replace the master cylinder if damage is found. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7238 ASSEMBLY PROCEDURE 1. Lubricate rubber parts with clean brake fluid to ease assembly. 2. Install the lubricated secondary seal (10) onto the secondary piston (9). 3. Install the lubricated primary seal (8) onto the primary piston (11). 4. Install the spring retainer (7) onto the secondary piston (9). 5. Install the lubricated secondary piston spring (6) into the cylinder bore. 6. Install the lubricated secondary piston assembly (9) into the cylinder bore. 7. Install the lubricated primary piston (11) into the cylinder bore. 8. Install the piston retainer (12) while depressing the primary piston. 9. Install the proportioner valve assemblies (15-19). Refer to Proportioning Valve Replacement 10. Install the fluid level switch. 11. Install the master cylinder reservoir diaphragm (2) into the reservoir cover (1). 12. Install the master cylinder reservoir diaphragm and the reservoir cover into the master cylinder reservoir. 13. Install the master cylinder. Refer to Master Cylinder Overhaul. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7239 Brake Master Cylinder: Service and Repair Master Cylinder Replacement REMOVAL PROCEDURE 1. Disconnect the battery. CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position. 2. Remove the air box. Refer to Air Cleaner Assembly Replacement. 3. Perform the gear tension release procedure. Refer to Antilock Brake System (ABS) and Enhanced Traction System (ETS). 4. Disconnect the electrical connector from the fluid level switch (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7240 5. Disconnect the electrical connectors from both of the ABS solenoids (1,2). 6. Remove the motor pack electrical connector (1). 7. Disconnect the brake pipe tube nuts (1) from the master cylinder and the modulator assembly (2). 8. Plug the open brake pipes (1 ) in order to prevent brake fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7241 9. Remove the master cylinder mounting nuts (3). 10. Remove the master cylinder (3) from the booster (2). INSTALLATION PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the master cylinder (3) to the booster assembly (2). ^ Tighten the master cylinder and the modulator assembly mounting nuts to 27 Nm (20 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7242 2. Install the brake pipe tube nuts (1) to the master cylinder and the modulator assembly (2). ^ Tighten the brake pipe tube nuts to 23 Nm (17 ft. lbs.). 3. Connect the electrical connector to the fluid level switch (1). 4. Connect the electrical connectors to both solenoids (1,2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7243 5. Connect the motor pack electrical connectors (1). 6. Fill the master cylinder to the proper level with clean brake fluid. 7. Bleed the hydraulic system. Refer to Brake Bleeding. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7244 Brake Master Cylinder: Service and Repair Brake Modulator/Master Cylinder ASM Replacement (with ABS) REMOVAL PROCEDURE CAUTION: To help avoid personal injury, due to a retained load on the brake modulator, the Gear Tension Relief function of the scan tool must be performed prior to removal of the ABS brake modulator/master cylinder assembly. 1. Use the Scan fool in order to perform the Gear Tension Relief Sequence. 2. Disconnect two brake solenoid valve electrical connectors (1), (3). 3. Disconnect the brake fluid level indicator sensor connector (2). 4. Disconnect the ABS brake motor pack 6-way electrical connector (6). 5. Remove four brake pipes (5). 6. Remove the two nuts (8) attaching the ABS brake modulator/master cylinder assembly (7) to the vacuum booster. 7. Remove the ABS brake modulator/master cylinder assembly (7). INSTALLATION PROCEDURE 1. Install the ABS brake modulator/master cylinder assembly (7) into the vehicle. Install the two nuts (8) attaching the ABS modulator master cylinder assembly (7). ^ Tighten the ABS brake modulator/master cylinder nuts (8) to 27 Nm (20 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7245 2. Install four brake pipes (5) onto the ABS brake modulator/master cylinder assembly (7). ^ Tighten the tube nuts to 24 Nm (18 ft. lbs.). 3. Connect the ABS brake motor pack 6-way electrical connector (6). 4. Connect the brake fluid level indicator sensor electrical connector (2). 5. Connect two brake solenoid valve electrical connectors (1), (3). Important: Bleed the system. Refer to Bleeding Brake Hydraulic System in Brake Bleeding. 6. Perform the Diagnostic System Check Master Cylinder Cover/Caps Replacement (Reservoir Cap Cleaning) REMOVAL PROCEDURE 1. Clean the master cylinder reservoir cap (1) before removal to avoid dirt entering the reservoir. 2. Remove the reservoir cap (1). 3. Remove the rubber diaphragm from cap (2). 4. Clean any brake fluid that exists between the cap and the rubber diaphragm with a dry lint free rag. 5. Inspect the brake fluid for the proper level. Remove fluid if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7246 1. Install the rubber diaphragm (1) into the reservoir cap (2). 2. Install the reservoir cap (2) to the reservoir (3). Master Cylinder Overhaul DISASSEMBLY PROCEDURE IMPORTANT: The master cylinder reservoir cover and reservoir diaphragm may be inspected and/or serviced without removing the master cylinder from the vehicle. 1. Remove the master cylinder completely from the vehicle. Refer to Master Cylinder Replacement. 2. Separate the modulator assembly from the master cylinder assembly Refer to Brake Modulator/Master Cylinder Asm Replacement in Antilock Brake System Traction Control. 3. Clean the master cylinder reservoir cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7247 4. Remove the master cylinder reservoir cover (1). 5. Remove the master cylinder reservoir diaphragm (2). 6. Empty the fluid from the reservoir. Empty the fluid only if the master cylinder is to be completely removed and overhauled. 7. Inspect the master cylinder cover and the diaphragm for the following conditions. Replace the parts as necessary: ^ Cuts ^ Cracks ^ Nicks ^ Deformation 8. Remove the fluid level switch (1). 9. Remove the proportioner valve assemblies. 10. Remove the piston retainer (12) while depressing the primary piston. Do not damage the primary piston (11), the master cylinder bore or the piston retainer groove (18). 11. Remove the primary piston (11). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 12. Remove the secondary piston (9). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 13. Remove the secondary piston spring (6) and the spring retainer (7). Apply low pressure non-lubricated compressed air into the upper outlet port at the blind end of the bore with all other outlet ports plugged. 14. Remove the secondary seal (10). 15. Remove the primary seal (8). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7248 16. Remove the spring retainer from the secondary piston (9). ^ Clean all parts in clean denatured alcohol. ^ Dry the parts with non-lubricated compressed air. ^ Do not use an abrasive on the bore. 17. Inspect the master cylinder bore for scoring or corrosion. Replace the master cylinder if damage is found. ASSEMBLY PROCEDURE 1. Lubricate rubber parts with clean brake fluid to ease assembly. 2. Install the lubricated secondary seal (10) onto the secondary piston (9). 3. Install the lubricated primary seal (8) onto the primary piston (11). 4. Install the spring retainer (7) onto the secondary piston (9). 5. Install the lubricated secondary piston spring (6) into the cylinder bore. 6. Install the lubricated secondary piston assembly (9) into the cylinder bore. 7. Install the lubricated primary piston (11) into the cylinder bore. 8. Install the piston retainer (12) while depressing the primary piston. 9. Install the proportioner valve assemblies (15-19). Refer to Proportioning Valve Replacement 10. Install the fluid level switch. 11. Install the master cylinder reservoir diaphragm (2) into the reservoir cover (1). 12. Install the master cylinder reservoir diaphragm and the reservoir cover into the master cylinder reservoir. 13. Install the master cylinder. Refer to Master Cylinder Overhaul. Master Cylinder Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7249 REMOVAL PROCEDURE 1. Disconnect the battery. CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position. 2. Remove the air box. Refer to Air Cleaner Assembly Replacement. 3. Perform the gear tension release procedure. Refer to Antilock Brake System (ABS) and Enhanced Traction System (ETS). 4. Disconnect the electrical connector from the fluid level switch (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7250 5. Disconnect the electrical connectors from both of the ABS solenoids (1,2). 6. Remove the motor pack electrical connector (1). 7. Disconnect the brake pipe tube nuts (1) from the master cylinder and the modulator assembly (2). 8. Plug the open brake pipes (1 ) in order to prevent brake fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7251 9. Remove the master cylinder mounting nuts (3). 10. Remove the master cylinder (3) from the booster (2). INSTALLATION PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the master cylinder (3) to the booster assembly (2). ^ Tighten the master cylinder and the modulator assembly mounting nuts to 27 Nm (20 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7252 2. Install the brake pipe tube nuts (1) to the master cylinder and the modulator assembly (2). ^ Tighten the brake pipe tube nuts to 23 Nm (17 ft. lbs.). 3. Connect the electrical connector to the fluid level switch (1). 4. Connect the electrical connectors to both solenoids (1,2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7253 5. Connect the motor pack electrical connectors (1). 6. Fill the master cylinder to the proper level with clean brake fluid. 7. Bleed the hydraulic system. Refer to Brake Bleeding. Master Cylinder Reservoir Filling NOTICE: Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone brake fluid. Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components to deteriorate. Keep all fluid containers capped to prevent contamination. ^ A properly filled master cylinder reservoir ensures adequate reserve, and prevents air and moisture from entering the hydraulic system. ^ Do not overfill the master cylinder reservoir. Heat that is absorbed from the brakes and the engine will cause the master cylinder reservoir to expand. ^ Do not add fluid if the brake hydraulic system is not leaking. ^ The master cylinder reservoir is a part of the master cylinder assembly. ^ The master cylinder reservoir is located under the hood on the driver's side of the vehicle. ^ Fill reservoir using Delco Supreme No. II Hydraulic Brake Fluid or the equivalent, DOT-3 motor vehicle brake fluid. 1. Thoroughly clean the master cylinder reservoir cover before removal in order to avoid getting dirt into the reservoir. 2. Remove the cover and the diaphragm. 3. Add the fluid as required in order to bring the level to 20-26 mm (0.78-1.0 in) below the filler neck inside the reservoir. Master Cylinder Reservoir Replacement REMOVAL PROCEDURE 1. Remove the master cylinder. Refer to Master Cylinder Replacement. Notice: Do not clamp on master cylinder body. Doing so may damage the master cylinder. 2. Clamp the flange of the master cylinder body in a vise (5). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7254 3. Drive out the spring pins (2) using a ,/e inch punch (4). Do not damage the reservoir or the cylinder body when driving out the spring pins. 4. Remove the master cylinder reservoir (1). Pull the master cylinder reservoir straight up and away from the master cylinder body. Remove the reservoir from the body. 5. Remove the O-rings from the grooves on the master cylinder reservoir (3). Discard the O-rings. 6. Clean the reservoir (3) with clean denatured alcohol. 7. Dry the reservoir (3) with non-lubricated compressed air. 8. Inspect the master cylinder reservoir (3) for cracks or deformation. Replace the reservoir (3) if damage is evident. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7255 INSTALLATION PROCEDURE 1. Lubricate the new O-rings (4) with clean brake fluid. 2. Lubricate the reservoir flanges with clean brake fluid. 3. Install the new O-rings (4) into the grooves on the master cylinder reservoir (3). Ensure that the O-rings (4) are properly seated. 4. Install the master cylinder reservoir (3) to the master cylinder body (2). Press straight down by hand into the master cylinder body (2). 5. Install the spring pins (2) using a 1/8 inch punch (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Modulator/Master Cylinder ASM Replacement (with ABS) > Page 7256 Do not damage the reservoir (1) or the master cylinder body (3). 6. Install the master cylinder. Refer to Master Cylinder Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7261 Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62 in.lb Wheel Cylinder to Backing Plate 15 ft.lb Inlet Tube Nut 17 ft.lb Wheel Cylinder Bore Diameter 0.689 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement Wheel Cylinder: Service and Repair Wheel Cylinder Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. 2. Clean any dirt or foreign material around the wheel cylinder assembly inlet and pilot. 3. Remove the inlet tube nut and line. Plug the opening in the line to prevent fluid loss and contamination. 4. Remove the brake drum. Refer to Brake Drum Replacement. 5. Remove the hub and bearing assembly. Refer to Rear Wheel Hub and Bearing Replacement. 6. Pull the backing plate (1) away from the axle flange. Do not let the backing plate hang from the parking brake cable as damage may occur. Refer to Drum Brake Backing Plate Replacement. 7. Remove the wheel cylinder bolts using a #6 Torch socket. 8. Remove the wheel cylinder (14). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7264 INSTALLATION PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the wheel cylinder bolts (8) using a #6 Torx socket. ^ Tighten the wheel cylinder bolts to 20 Nm (15 ft. lbs.). 2. Install the backing plate (11) to the axle flange. 3. Install the hub and bearing assembly. Refer to Rear Wheel Hub and Bearing Replacement. 4. Install the brake drum. Refer to Brake Drum Replacement. 5. Install the inlet tube line and nut. ^ Tighten the inlet tube nut to 23 Nm (17 ft. lbs.). CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. 6. Bleed the wheel cylinder and then the complete brake system. Refer to Brake Bleeding. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7265 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY PROCEDURE 1. Remove the wheel cylinder from the vehicle. Refer to Wheel Cylinder Replacement. 2. Remove the wheel cylinder boots (4). 3. Remove the wheel cylinder pistons (3) and seals (2). 4. Remove the wheel cylinder spring assembly (5). 5. Remove the wheel cylinder bleeder valve (6). 6. Inspect the cylinder bore (1) and pistons (3) for scoring, nicks, corrosion and wear. Use a crocus cloth in order to polish out light corrosion. Replace the wheel cylinder assembly if the bore will not clean up using the crocus cloth. 7. Clean all the parts in clean, denatured alcohol. 8. Dry the parts with unlubricated, compressed air. CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne If dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment Is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne. Notice: Brake fluid will damage painted surfaces. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 9. Lubricate the new seals (2) with clean brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Replacement > Page 7266 ASSEMBLY PROCEDURE NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 1. Install the bleeder valve (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 2. Install the spring assembly (5). 3. Install the seals (2), pistons (3) and boots (4). 4. Install the wheel cylinder to the vehicle. Refer to Wheel Cylinder Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments 1. Fully apply and release the hand brake 4-6 times in order to self adjust. 2. The parking brake is self adjusting. However if the parking brake tension is in question, refer to Hydraulic Park Brake Diagnostic in Parking Brake System Testing and Inspection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) Parking Brake Cable: Service and Repair Park Brake Cable Replacement (Front) REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting and Jacking. 2. Pull and hold the cable towards the rear of the car in order to create slack in the cable. 3. Bend the tang (2) on the connector (1) in order to allow cable removal. 4. Disconnect the cable (3) from the connector (1). 5. Fold over the retaining clip. 6. Disconnect the cable (3) from the equalizer. 7. Lower the vehicle. 8. Remove the console. If you are repairing a Pontiac, also remove the shifter boot. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7273 9. Move the lever to the OFF position. 10. Remove the cable conduit end fitting (2) from the lever assembly (1). 11. Pull the cable (3) until the notch on the ratchet (1) is visible through the cover plate opening (4). 12. Push the pawl spring downward toward the notch in the ratchet. 13. Release the cable (3) slowly in order to allow the notch to catch the leg of the spring (5). 14. Remove the front parking brake cable button (2) from the reel assembly. 15. Remove the left rocker panel/door sill plate. 16. Remove the grommet and retainer from the floor pan. 17. Remove the cable from the clip on #2 bar, under the carpet. 18. Remove the front cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7274 INSTALLATION PROCEDURE 1. Install the cable through the floor pan, from the interior to the exterior. 2. Install the cable conduit fitting (2) to the lever assembly (1). 3. Install the front parking brake cable button to the reel assembly. 4. Install the cable into the #2 bar clip under the carpet. 5. Install the console. If you are repairing a Pontiac, also install the shifter boot. 6. Install the left rocker panel door sill plate. 7. Raise the vehicle. 8. Fold over the bracket to the body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7275 9. Install the cable (3) to the equalizer assembly. 10. Install the cable to the connector (1). 11. Bend the tang (2) on the connector (1) in order to retain the cable. 12. Lower the vehicle. NOTICE: Parking brake adjustment is not necessary. This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust the rear brakes to obtain the proper tension in the system. Refer to Brake Adjustment, Leading Trailing Drum Brake Assembly. 13. Fully apply and release the hand brake 4-6 times in order to activate the self adjust system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7276 Parking Brake Cable: Service and Repair Park Brake Cable Replacement (Rear) REMOVAL PROCEDURE 1. Remove the console. If you are repairing a Pontiac, also remove the shifter boot. 2. Move the lever to the OFF position. 3. Remove the cable conduit fitting (2) from the handle assembly (1). 4. Pull the cable (3) until the notch on the ratchet (1) is visible through the cover plate opening (4). 5. Push the pawl spring downward toward the notch in the ratchet. 6. Release the cable (3) slowly to allow the notch (1) in order to catch the leg of the spring (5). 7. Raise and suitably support the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7277 8. Bend the tang (2) on the connector (1) to allow cable removal. 9. Pull and hold the cable towards the rear of the car in order to create a slack in the cable. 10. On the right rear, remove the cable (3) from the connector (1). On the left rear, remove the cable from the equalizer. 11. Remove the brake drum. Refer to Brake Drum Replacement. 12. Remove the tire and wheel assembly. Refer to Wheel Removal. 13. Insert a screwdriver between the brake shoe and the lower part of the rear park brake lever. 14. Remove the cable eyelet fitting from the rear park brake lever. 15. Remove the conduit fitting from the backing plate while depressing the retaining tangs of the conduit fitting. INSTALLATION PROCEDURE 1. Install the conduit fitting into the backing plate. 2. Install the parking brake cable to the parking brake lever in the drum assembly. 3. Install the tire and wheel assembly. Refer to Wheel Installation. 4. Install the brake drum. Refer to Brake Drum Replacement. 5. Install the conduit fitting into the axle bracket. 6. Connect the left rear cable to the equalizer. 7. Connect the right rear cable to the connector. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement (Front) > Page 7278 9. Install the console. If you are repairing a Pontiac, also install the shifter boot. 10. Fully apply and release the hand brake 4-6 times in order to self adjust the system. Notice: Parking brake adjustment is not necessary. This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust the rear brakes to obtain the proper tension in the system. Refer to Brake Adjustment, Leading Trailing Drum Brake Assembly. 11. Check the parking brake tension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking brake lever mounting nuts .......................................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 7282 Parking Brake Lever: Service and Repair REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Pull and hold the cable towards the rear of the car in order to create slack in the cable. 3. Bend the tang (2) on the connector (1) in order to allow cable removal. 4. Disconnect the cable (3) from the connector (1). 5. Lower the vehicle. 6. Remove the console. If you are repairing a Pontiac, also remove the shifter boot. 7. Move the lever to the OFF position. 8. Remove the cable conduit end fitting (2) from the handle assembly (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 7283 9. Pull the cable (3) until the notch on the ratchet (1) is visible through the cover plate opening (4). 10. Push the pawl spring downward toward the notch in the ratchet. 11. Release the cable (3) slowly to allow the notch (1) to catch the leg of the spring (5). 12. Remove the front parking brake cable button (2) from the reel assembly. 13. Remove the electrical connector. 14. Remove the nuts (1) securing the lever (2). 15. Remove the lever (2). INSTALLATION PROCEDURE 1. Ensure that the pawl spring (5) is properly engaged. (Pull the cable until the notch on the ratchet (1) is visible through the cover plate opening (4). Push the pawl spring (5) downward toward the notch in the ratchet (1). Release the cable slowly to allow the notch to catch the leg of the spring (5~.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 7284 2. Install the front parking brake cable (4) to the lever assembly (2) and secure the cable conduit fittings into the lever assembly (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the parking brake lever (2) and attaching nuts (1). ^ Tighten the parking brake lever nuts to 25 Nm (18 ft. lbs.). 4. Install the electrical connector. 5. Raise and support the vehicle. Lifting an Jacking in General Information. 6. Connect the cable (4) to the connector (2). 7. Lower the vehicle. Notice: Parking brake adjustment is not necessary. This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust the rear brakes to obtain the proper tension in the system. Refer to Brake Adjustment, Leading Trailing Drum Brake Assembly. 8. Fully apply and release the hand brake 4-6 times in order to activate the self adjust system. 9. Install the console. If you are repairing a Pontiac, also install the shifter boot. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations At the left center of the console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 7292 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Fastener Tightening Specifications Vacuum Booster Retaining Nuts ............................................................................................................................................................. 27 N.m (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7297 Over Head Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7298 Vacuum Brake Booster: Description and Operation IMPORTANT: ^ Do not use lubricated compressed air on the brake parts. Damage to the rubber parts may result. ^ Bleed all or part of the brake system if any hydraulic component is removed or disconnected. ^ The torque values specified are for dry non-lubricated fasteners. ^ Perform service operations on a clean bench, free from all mineral oil materials. The booster (9) for this vehicle is a tandem suspended unit. In a normal operating mode, with the service brakes in the released position, the tandem vacuum suspended booster operates with a vacuum on both sides of the diaphragms. When the brakes are applied, air at the atmospheric pressure is admitted to one side of each diaphragm in order to provide the power assist. When the service brake is released, the atmospheric air is shut off from one side of each of the diaphragm. Air is then drawn from the booster through the vacuum check valve to the vacuum source. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Vacuum Booster Diagnosis (Hard Pedal) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Vacuum Booster Diagnosis (Hard Pedal) > Page 7301 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Vacuum Booster Diagnosis (Hard Pedal) > Page 7302 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7303 Vacuum Brake Booster: Service and Repair REMOVAL PROCEDURE 1. Disconnect the battery. CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position. 2. Remove the air box. Refer to Air Cleaner Assembly Replacement in Engine Controls. Important: Do not remove or disconnect the master cylinder from the vehicle in order to remove the vacuum booster. If the master cylinder and the vacuum booster are both being services, remove the master cylinder first. Refer to Master Cylinder Replacement. 3. Remove the master cylinder attaching nuts 4. Remove the master cylinder (10) from the booster (9). 5. Move the master cylinder forward just enough in order to clear the studs on the vacuum booster. This will flex the brake pipes slightly. Do not bend or distort the brake pipes. 6. Do not lose or dislodge the insulator (3,4) that is between the booster and the front of the dash. 7. Remove the vacuum hose from the vacuum check valve. Refer to Vacuum Brake Booster Operation (Hose). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7304 8. Remove the booster attaching nuts (7). 9. Remove the booster pushrod (2) from the brake pedal. Tilt the entire vacuum booster slightly in order to work the booster pushrod off of the pedal clevis pin without putting undue pressure on the pushrod. 10. Remove the booster from the vehicle. INSTALLATION PROCEDURE 1. Install the booster into the vehicle. 2. Install the booster pushrod (2) to the brake pedal. Tilt the entire vacuum booster slightly in order to work the booster pushrod on to the pedal clevis pin without putting undue pressure on the pushrod. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7305 instructions can help you avoid damage to parts and systems. 3. Install the booster attaching nuts (7). ^ Tighten the booster to brake pedal attaching nuts to 27 Nm (20 ft. lbs.). 4. Install the booster vacuum hose to the vacuum check valve (2). 5. Install the master cylinder (1) to the booster (3). 6. Install the master cylinder attaching nuts (2). ^ Tighten the master cylinder to the booster attaching nuts to 27 Nm (20 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair REMOVAL PROCEDURE 1. Remove the vacuum check valve (3). 2. Remove the grommet (1). 3. Remove the boot and the air filter. 4. Remove the front housing seal (2). 5. Inspect the boot, the front housing seal (2), and the grommet for the following conditions. Replace the components as necessary: ^ Cuts ^ Nicks ^ Excessive wear 6. Clean the boot with denatured alcohol. Dry the boot with non-lubricated compressed air. 7. Clean the front housing seal (2) using denatured alcohol. Dry the front housing seal (2) with non-lubricated compressed air. 8. Clean the grommet using denatured alcohol. Dry the grommet with non-lubricated compressed air. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 7309 INSTALLATION PROCEDURE 1. Lubricate the inside and the outside diameters of the grommet and the front housing seal using a thin layer of silicone grease. 2. Install the front housing seal. 3. Install the air filter and the boot. 4. Install the booster. Refer to Vacuum Brake Booster Replacement. 5. Install the grommet (2). 6. Install the vacuum check valve (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7322 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7323 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7329 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7330 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7331 Electronic Brake Control Module: Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7332 Component Location Views Left hand lower I/P Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module (EBCM) (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7335 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM) (C2) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7336 Electronic Brake Control Module (EBCM) (C2) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement REMOVAL PROCEDURE 1. Remove the dash wiring harness connectors from the EBCM. 2. Remove the EBCM from the bracket. INSTALLATION PROCEDURE 1. Install the EBCM to the bracket. 2. Install the dash wiring harness connectors to the EBCM. 3. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Electronic Brake Control Module Replacement > Page 7339 Electronic Brake Control Module: Service and Repair Electronic Brake Control Relay Replacement REMOVAL PROCEDURE 1. Remove the underhood fuse block cover. 2. Remove the electronic brake control relay from the underhood fuse block. INSTALLATION PROCEDURE 1. Install the electronic brake control relay into the underhood fuse block. 2. Install the underhood fuse block cover. 3. Perform the "Diagnostic System Check" in Antilock Brake System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Switch Location Left hand rear of engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 7345 Brake Fluid Level Sensor/Switch: Locations Brake Fluid Level Indicator, ABS Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Brake Fluid Level Switch Location > Page 7346 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7347 Brake Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7348 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector from the fluid level switch (1). 2. Disconnect the fluid level switch using needle nose pliers in order to compress the switch locking tabs (1) at the inboard side of the master cylinder. INSTALLATION PROCEDURE 1. Connect the fluid level switch into the master cylinder reservoir until the locking tabs (3) snap into place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7349 2. Connect the electrical connector to the fluid level switch (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Technical Service Bulletins > Twist-Lock Style Brake Switches - Proper Adjustment Braking Sensor/Switch: Technical Service Bulletins Twist-Lock Style Brake Switches - Proper Adjustment File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-12 Date: April, 1998 INFORMATION Subject: Proper Adjustment of New Twist-Lock Style Brake Switches Models: 1996-98 Buick LeSabre, Park Avenue, Riviera 1996-98 Cadillac DeVille, Eldorado, Seville 1997-98 Chevrolet Malibu 1998 Chevrolet Cavalier 1996 Oldsmobile Ninety Eight 1996-98 Oldsmobile Aurora, Eighty Eight, LSS, Regency 1997-98 Oldsmobile Cutlass 1999 Oldsmobile Alero 1996-98 Pontiac Bonneville 1998 Pontiac Sunfire 1999 Pontiac Grand Am This bulletin is being issued to advise that new style brake switches were used beginning in the 1996 model year. The two switches control the brake lights, cruise control engage/release, TCC lock-up/release and the Brake/Transmission Inter-Lock function. The switches are adjusted by twisting rather than ratcheting. Using the old adjustment method of pulling up on the brake pedal can break the switch. A mis-adjusted or damaged switch may cause customer comments such as: ^ Brake lights stay on, draining the battery ^ Cruise control inoperative ^ Higher than normal fuel consumption if TCC cannot engage ^ Brake drag ^ Cruise control takes excess pedal travel to release The adjustment procedure in the Service Manual should be followed. Procedure 1. Insert the stop lamp switch into the retainer until the switch bottoms out against the brake pedal, and the switch actuator is fully depressed. 2. Turn the brake switch in the retainer clockwise until the travel stop has been reached. At this point it will be locked. Important: If the switch is not fully locked into position, a clicking noise may result. 3. The brake switch plunger should extend outward 0.5 mm to 1.5 mm (0.02 in. to 0.06 in.) if adjusted correctly. 4. If the distance the plunger extends is too great, the brake switch must be turned counter-clockwise about 45° and set to the correct distance before locking it in place by turning it clockwise until the travel stop is reached. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations At the left center of the console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 7361 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component Location Views At the center console on the gear selector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 7365 Enhanced Traction Control System Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Retaining Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor Wheel Speed Sensor: Locations Wheel Speed Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 7371 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor > Page 7372 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF LF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 7375 RF Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 7376 LR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > LF > Page 7377 RR Wheel Speed Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Front) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Disconnect the front wheel speed sensor electrical connector. 3. Remove the retaining bolt. 4. Remove the front wheel speed sensor. If the sensor will not slide out of the knuckle, remove the brake rotor and use a blunt punch or equivalent tool to push the sensor from the back side of the knuckle. IMPORTANT: If the sensor locating pin breaks off and remains in the knuckle during removal, proceed as follows: 1. Remove the brake rotor and remove broken pin using a blunt punch. 2. Clean the hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALLATION PROCEDURE 1. Install the front wheel speed sensor to the steering knuckle. 2. Install the retaining bolt. ^ Tighten the Torx screws to 12 Nm (107 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Connect the front wheel speed sensor electrical connector. 4. Lower the vehicle. 5. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7380 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (Rear) IMPORTANT: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to Rear Suspension in Suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7381 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting And Jacking. 2. Remove the connector from the front wheel speed sensor. 3. Remove the harness attaching clips (2) from the control arm (3) and the splash shield (1). 4. Lower the vehicle. 5. Remove the harness attaching clips from the strut tower. 6. Cut the wheel speed sensor wiring circuits within the main engine harness. 7. Strip the insulation on the engine harness leads and the new wheel speed sensor harness leads. INSTALLATION PROCEDURE 1. Splice the sleeve provided in the jumper harness kit over each engine harness lead. 2. Install the new wheel speed sensor harness leads to the engine harness leads and crimp the connections. Make sure the wire colors match. 3. Heat shrink the tube lightly to seal the connection. 4. Install the harness attaching clip to the strut tower. 5. Raise and support the vehicle. Refer to Vehicle Lifting And Jacking. 6. Install the harness attaching clips (2) to the control arm (3) and the splash shield (1). 7. Install the connector to the front wheel speed sensor. 8. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 9. Perform the Diagnostic System Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement (Front) > Page 7382 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Jumper Harness Replacement (Rear Axle) REMOVAL PROCEDURE 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting and Jacking. 2. Disconnect the two rear wheel speed sensor electrical connectors (3) from the rear wheel bearing and speed sensor assemblies (2). 3. Disconnect the rear axle harness electrical connector from the body to ABS and fuel sender connector. 4. Remove the rear axle harness retainers (1). 5. Remove the rear axle harness from the vehicle. INSTALLATION PROCEDURE 1. Install the rear axle harness to the vehicle. 2. Install the rear axle harness retainers (1). 3. Connect the rear axle harness electrical connector to the body to ABS and fuel sender connector. 4. Connect the two rear wheel speed sensor electrical connectors (3) to the rear wheel bearing and speed sensor assemblies (2). 5. Lower the vehicle. Refer to Vehicle Lifting And Jacking. 6. Perform the Diagnostic System Check. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 7388 Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch ............................................................................................................................. ...........................................................4 N.m (35 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Specifications Negative: Specifications Negative Battery Cable Terminal Nut .................................................................................................. .........................................................16 N.m (12 lb ft) Negative Battery Cable to Tray Bolt ................ .............................................................................................................................................35 N.m (26 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Specifications > Page 7435 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > Customer Interest for Battery Cable, Positive: > 83-64-16 > Jun > 98 > Battery Weak, Discharged/Slow Starting/GEN or MIL On Positive: Customer Interest Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable, Positive: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Positive: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > Page 7449 Positive: Specifications Positive Battery Cable Terminal Nut .................................................................................................... ........................................................20 N.m (15 lb ft) Positive Battery Cable to Starter Solenoid Nut ..........................................................................................................................................12 N.m (106 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > Page 7450 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement Alternator: Technical Service Bulletins Warranty - Generator Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-011 Date: October, 1999 Subject: CS-144 Generator Replacement Models: 1998-2000 Passenger Cars and Trucks Beginning with the 1998 model year, General Motors stopped releasing internal repair components for the CS-144 Generator. GM warranty procedures require the replacement of the CS-144 generator. The generator unit repair procedures found in the past model Service Manuals should not be used. Use of non-GM repair parts for warranty repairs is not approved or recommended. Therefore, warranty labor claims for CS-144 generator rebuilds in the field for 1998 and newer vehicles will not be accepted. Service parts which may be available through GM for past model years, which appear to fit, should not be used. The use of correct parts is essential for proper performance of the generator. This policy change was instituted by GM to provide the best service and warranty experience for our customers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement > Page 7456 Alternator: Technical Service Bulletins Tools - Released for CS Generator Diagnosis File In Section: 6 - Engine Bulletin No.: 83-64-09 Date: March, 1998 INFORMATION Subject: New Tool J 41450-B, Released for CS Generator Diagnosis Models: 1988-98 Passenger Cars and Light Trucks with CS-Series Generators A new CS-Series Generator Tester, J 41450-B, has been sent to all dealers as part of the Essential Tool Package. This tool will work on all CS-Series generators for past model years. The tool is shown in Figure 1. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement > Page 7457 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement > Page 7458 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement > Page 7459 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Warranty - Generator Replacement > Page 7460 Generator Not Operating Properly The charts shown can be used in place of the diagnostic procedures in previous Service Manuals when this new tool is used. This information will be included in the 1999 Service Manual. Inspect the following before testing the generator: ^ The battery. Make sure the vehicle battery is in good condition and fully charged. Refer to Battery Load Test. ^ The built in hydrometer in the battery. The green eye must be showing in the hydrometer. ^ The voltage across the battery terminals with all the loads OFF should be above 12 V. Refer to Battery Load Test. ^ Make sure the battery connections are clean and tight. ^ The drive belt for damage or looseness. ^ The wiring harness at the generator. Make sure the harness connector is tight and latched. Make sure the output terminal of the generator is connected to the vehicle battery (positive) generator lead. ^ All the charging system related fuses and electrical connections for damage or looseness. Refer to the starter and charging system schematics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Amperage 2.2L 4-cyl (LN2) and 2.4L 4-cyl (LD9) Model ................................................................................................................................................... .....................................................................CS13OD Rated Output ................................................... .............................................................................................................................................................. ..105A Charging Voltage 13.0-16.0 Volts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 7463 Alternator: Mechanical Specifications Front Generator Bracket to Block Attaching Bolt .........................................................................................................................................50 N.m (37 lb ft) Generator (Upper) Front Mounting Bolt .......................................................................................................................................................30 N.m (22 lb ft) Generator (Lower) Front Mounting Bolt .......................................................................................................................................................50 N.m (37 lb ft) Rear Generator Bracket to Block Attaching Bolt .........................................................................................................................................85 N. m (63 lb ft) Rear Generator Bracket to Block Attaching Nut ...........................................................................................................................................43 N.m (32 lb ft) Rear of Generator to Bracket Bolt ............................................................................................... .................................................................30 N.m (22 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 7464 Alternator: Locations Component Location Views On the top RH side of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 Alternator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 Generator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7499 Alternator: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution In Cautions and Notices. 1. Disconnect the negative battery cable at the battery. 2. Disconnect the generator electrical connections. 3. Remove the generator drive belt. 4. Remove the through bolts that retain the generator. 5. Remove the generator. INSTALLATION PROCEDURE 1. Install the generator to the mounting bracket with the bolts and the washers. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. install the generator nuts. Tighten Tighten the generator nuts (2) to 43 N.m (32 lb ft). - Tighten the generator bolt (5) to 50 N.m (37 lb ft). - Tighten the generator bolt (1) to 30 N.m (22 lb ft). 3. Install the generator drive belt. CAUTION: Before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with "live" or "hot all the times" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the OFF or LOCK position. 4. Connect the generator electrical connections. 5. Connect the negative cable at the battery. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 7504 Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7514 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7515 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7516 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch ............................................................................................................................. ...........................................................4 N.m (35 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Specifications Starter Cable: Specifications Starter Lead Wire to Starter Solenoid S Terminal Nut ................................................................................................................................2.5 N.m (22 lb in) Starter Field Lead to Solenoid Attaching Screw .............................................................................................................................................9 N.m (80 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Bearing > Component Information > Specifications Starter Bearing: Specifications Commutator End Frame/Field Frame Assembly Through Bolts .....................................................................................................................9 N.m (80 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Positive Battery Cable to Starter Solenoid Nut ..........................................................................................................................................12 N.m (106 lb in) Solenoid Attaching Screws ......................................................................................................... ....................................................................7 N.m (62 lb in) Starter Field Lead to Solenoid Attaching Screw .............................................................................................................................................9 N.m (80 lb in) Starter Lead Wire to Starter Solenoid S Terminal Nut ................................................................................................................................2.5 N.m (22 lb in) Starter Motor Solenoid to the S Terminal Nut ................................................................................................................................................3 N.m (27 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 7563 Starter Solenoid: Locations Component Location Views On the lower front of the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions Starter Solenoid: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7566 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7567 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7568 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7569 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 Starter Solenoid: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero Diode: Customer Interest Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest for Diode: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero > Page 7619 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 99-08-49-012 > Sep > 99 > Trip Odometer Resets to Zero Diode: All Technical Service Bulletins Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diode: > 99-08-49-012 > Sep > 99 > Trip Odometer Resets to Zero > Page 7625 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations In the right front of the passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: Customer Interest Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: All Technical Service Bulletins Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7653 Fuse: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7654 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7655 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 7658 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Electrical Specifications Fuse Block: Electrical Specifications Front View Of Engine Compartment Fuse/Relay Center Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Electrical Specifications > Page 7663 Fuse Block: Mechanical Specifications Convenience Center to I/P .................................................................................................................. ............................................................6 N.m (53 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center Convenience Center At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 7666 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 7667 Fuse Block: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 Fuse Block: Diagrams C1 Convenience Center (C1) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 > Page 7670 Convenience Center (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 > Page 7671 Convenience Center (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 7674 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 7675 Fuse Block: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Remove the battery ground negative cable. 2. Remove the instrument panel compartment. 3. Remove the instrument panel access hole cover from the instrument panel. 4. Remove the electrical connectors. 5. Remove the fuse block from the tie bar (6). 6. Remove the fuse block (5) from the instrument panel. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 7676 1. Install the fuse block (5) to the instrument panel. 2. Install the fuse block to the tie bar (2). 3. Install the electrical connectors. 4. Install the right instrument panel access hole cover to the instrument panel. 5. Install the battery ground negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7684 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7685 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7686 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7687 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7688 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7689 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 7696 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 7702 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7711 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7712 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7713 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7714 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7715 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7716 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7717 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7718 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7719 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7720 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7721 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7722 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7723 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7724 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7725 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7726 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7727 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7728 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7729 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7730 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7731 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7732 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7733 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7734 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7735 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7736 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7737 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7738 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7739 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7740 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7746 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7747 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7748 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7754 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7755 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7756 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7761 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7762 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7763 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7764 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7765 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7766 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 7771 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7776 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7777 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7778 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7779 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7780 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7781 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7782 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7783 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7784 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7785 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7786 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7787 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7788 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7789 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7790 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7791 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7792 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7793 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7794 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7795 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7796 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7797 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7798 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7799 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7800 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7801 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7802 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7803 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7804 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 7805 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7811 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7812 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7813 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7818 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7819 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7820 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7821 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7822 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7823 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 7828 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7834 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7835 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7836 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7837 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7838 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 7839 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 7844 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7849 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7850 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7851 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7852 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7853 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7854 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7855 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7856 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7857 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7858 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7859 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7860 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7861 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7862 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7863 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7864 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7865 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7866 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7867 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7868 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7869 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7870 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7871 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7872 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7873 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7874 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7875 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7876 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7877 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall Ignition Circuit Defect > Page 7878 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero Diode: Customer Interest Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero > Page 7901 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero Diode: All Technical Service Bulletins Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero > Page 7907 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7913 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7914 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7920 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7921 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations In the right front of the passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: Customer Interest Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 73-64-06 > Dec > 97 > Electrical - Driveability, No Start, Blown Pump Fuse Fuse: All Technical Service Bulletins Electrical - Driveability, No Start, Blown Pump Fuse File In Section: 6 - Engine Bulletin No.: 73-64-06 Date: December, 1997 Subject: Various Electrical and/or Driveability Concerns (Repair Engine Wiring Harness) Models: 1998 Chevrolet Cavalier 1998 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers of J cars with the LN2 2200 engine may experience a blown fuel pump fuse, no start, or driveability concerns. Cause Condition may due to two areas of engine wiring damage. The # 4 fuel injector/EGR harness may contact the RH front corner of the brake master cylinder, resulting in damage to one or more of the wires in the harness bundle. Also, the main engine wire harness may contact the transaxle cooler line bracket near the transaxle on vehicles with the 4 speed automatic transmission. Correction To repair the # 4 injector/EGR harness, repair the wire using Service Manual procedures and install a 60 mm (2.5 in.) section of flexible polypropylene or nylon conduit (suitable for high temperature, underhood usage) over the harness to prevent further damage. Make sure that EGR and injector wires are both captured by the conduit. Tape the ends of the conduit. To repair the main engine wire harness chafing against the transaxle oil cooler line bracket, repair the wire using Service Manual procedures and use a plastic tie strap to secure the main engine wire harness to the battery cables. This will locate the engine wire harness away from the cooler line bracket at the transaxle. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N6270 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7949 Fuse: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7950 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 7951 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 7954 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Electrical Specifications Fuse Block: Electrical Specifications Front View Of Engine Compartment Fuse/Relay Center Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Electrical Specifications > Page 7959 Fuse Block: Mechanical Specifications Convenience Center to I/P .................................................................................................................. ............................................................6 N.m (53 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center Convenience Center At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 7962 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 7963 Fuse Block: Locations Engine Compartment Fuse Relay Center Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 Fuse Block: Diagrams C1 Convenience Center (C1) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 > Page 7966 Convenience Center (C1) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > C1 > Page 7967 Convenience Center (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 7970 Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 7971 Fuse Block: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Remove the battery ground negative cable. 2. Remove the instrument panel compartment. 3. Remove the instrument panel access hole cover from the instrument panel. 4. Remove the electrical connectors. 5. Remove the fuse block from the tie bar (6). 6. Remove the fuse block (5) from the instrument panel. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 7972 1. Install the fuse block (5) to the instrument panel. 2. Install the fuse block to the tie bar (2). 3. Install the electrical connectors. 4. Install the right instrument panel access hole cover to the instrument panel. 5. Install the battery ground negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7980 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7981 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7982 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7983 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7984 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 7985 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 7992 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Component Location Views LH front of the engine compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center Relay Box: Application and ID Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Fuse Block Details Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Engine Compartment Fuse/Relay Center > Page 7998 Relay Box: Application and ID Engine Compartment Fuse/Relay Center (Alt Fuel) Left Front Corner, Behind Headlamp 1. Ignition Relay 2. Fuel Pump Relay 3. Lock-off Relay 4. Fuel Gauge Relay 5. C023 6. C011 7. C007 8. C004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8007 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8008 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8009 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8010 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8011 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8012 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8013 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8014 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8015 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8016 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8017 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8018 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8019 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8020 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8021 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8022 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8023 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8024 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8025 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8026 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8027 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8028 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8029 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8030 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8031 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8032 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8033 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8034 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8035 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8036 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8042 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8043 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8044 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8050 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8051 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8052 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8057 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8058 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8059 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8060 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8061 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8062 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8067 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8072 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8073 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8074 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8075 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8076 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8077 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8078 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8079 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8080 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8081 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8082 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8083 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8084 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8085 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8086 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8087 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8088 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8089 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8090 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8091 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8092 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8093 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8094 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8095 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8096 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8097 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8098 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8099 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8100 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8101 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8107 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8108 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8109 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8114 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8115 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8116 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8117 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8118 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8119 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8124 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8130 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8131 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8132 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8133 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8134 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8135 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8140 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect Technical Service Bulletin # 04002 Date: 040218 Recall - Ignition Circuit Defect Product Safety - Ignition Circuit Thermal Events # 04002 - (02/18/2004) 04002 -- Ignition Circuit Thermal Events 1998 Buck Skylark 1998-2001 Chevrolet Cavalier 1998 Oldsmobile Achieva 1998 Pontiac Grand Am 1998-2001 Pontiac Sunfire Due to part availability, this recall is being conducted in three phases. Phase 1 will consist of 1998-1999 vehicles, phase 2 will consist of 2000 vehicles; and phase 3 will consist of 2001 vehicles. When sufficient parts are available to notify customers of 2000 and 2001 vehicles, you will be notified and will receive a new initiation report. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car, which could injure occupants of the car or cause damage to adjoining structures. Correction Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8145 Involved are certain 1998 model year Buick Skylark; 1998-2001 model year Chevrolet Cavalier; 1998 model year Oldsmobile Achieva; 1998 model year Pontiac Grand Am; and 1998-2001 model year Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. For Canada & IPC Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8146 These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts Pre-Ship Information - For US and Canada Important An initial supply of harness kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is equal to 20% of your involved vehicles and is scheduled to begin the week of February 6, 2004. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO=Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8147 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8148 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs for ignition switch replacement and related wiring repairs due to the condition addressed in this bulletin are to be submitted by June 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Pre of of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important Refer to the GM Service Policies and Procedures Manual. section 1.6.2 for specific procedures regarding customer reimbursement verification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8149 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8150 outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is... ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8151 Disclaimer Information 1. Open the hood. 2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test. Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership or another source. 3. Disconnect the negative battery cable. Caution The oil filter, exhaust manifold, and exhaust pipe may be hot. Use care to avoid personal injury. 1998 N Car - Achieva/Grand AM/Skylark with 3.1L V6 (VIN Code M) 1998 N Car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M) 1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit. Tighten Tighten the bolt to 10 Nm (89 lb in). 3. Locate the short black wire with a ring terminal on one end from the harness kit. 4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8152 upper radiator support bar just to the left (driver side) of the air bag support bracket. Tighten Tighten the bolt to 10 Nm (89 lb in). 5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness. 6. Raise the vehicle on a suitable hoist. 7. Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal. 8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 11. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. 12. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16. 16. Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal. 17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22. 22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8153 In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 28. Lower the vehicle. 29. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, no further action is required. ^ If the starter will NOT crank the engine, skip to Procedure A for N Car Achieva/Grand Am/Skylark. 1998 N Car - Achieva/Grand AM/Skylark with 2.4L(VIN Code T) 1998 N Car - Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8154 6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit. 7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit. Tighten Tighten the screw to 10 Nm (89 lb in). 8. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire. 10. Route the new wiring harness down to the starter motor. 11. Remove the top starter bolt. 12. Raise the vehicle on a suitable hoist. 13. Remove the oil filter. 14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace. 15. Remove the bottom starter bolt and remove the starter. 16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 17. Visually inspect the condition of the "S "terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding. 18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal. 19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 20. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8155 21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 22. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25. 25. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal. 27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness. 28. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Step 18-24 earlier, proceed to Step 30. 30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure that the "S" terminal is snug to the starter solenoid cap. 31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8156 36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter. Tighten Tighten to 9Nm (80 lb in). 38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 39. Lower the vehicle. 40. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 41. Raise the vehicle. 42. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold. Tighten ^ Tighten the two bolts attaching the brace to the intake manifold to 24 Nm (18 lb ft). ^ Tighten the two bolts to the engine block to 26 Nm (19 lb ft). 44. Install a new oil filter. 45. Lower the vehicle. 46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 48. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 49. Connect the air cleaner outlet duct to the air cleaner housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8157 Tighten Tighten the clamp to 5 Nm (44 lb in). 50. Connect the electrical connector to the sensor in the air cleaner outlet duct. 51. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 52. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark 54. Check the engine oil level and add as necessary. 1998 N Car - Achieva/Grand AM/Skylark - Procedure A(All Engine) 1998 N Car - Achieva/Grand Am/Skylark - PROCEDURE A (all engines) 1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15 amp AIR BAG fuse. 2. Remove the left side dash lower insulation panel. 3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector. 4. Remove the left side knee bolster trim panel. 5. If equipped, remove the tilt steering column lever. 6. Remove the bezel around the key lock cylinder. 7. Remove the screws that hold the steering column trim in place. 8. Remove both halves of the steering column trim. 9. Disconnect the wiring from the ignition switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8158 10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column. Notice The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws. Tighten Tighten both screws to 1.4 Nm (12 lb in). 12. Attach the wiring harness connectors to the ignition switch. 13. Reinstall the upper and lower steering column covers. Tighten Tighten the fasteners to 9 Nm (80 lb in). 14. Reinstall the knee bolster trim. Tighten Tighten the fasteners to 2 Nm (18 lb in). 15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA. 16. Reinstall the sound insulator panel. Tighten Tighten the fasteners to 2 Nm (18 lb in). 17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover. 18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. 1998 - 2001 J-Car - Cavalier/Sunfire With 2.4L (VIN Code T) 1998 J-Car - Cavalier/Sunfire with 2.4L Engine VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8159 3. loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8160 13. Using the 10 mm (hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Important The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 15. Remove the top starter bolt. 16. Raise the vehicle on a suitable hoist. 17. Remove the oil filter. 18. Remove the bottom starter bolt and remove the starter. 19. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 20. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 28 and remove the nut. Do NOT perform Steps 21-27 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 21 of this procedure. Steps 21-27 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 21. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 22. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8161 23. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 24. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 25. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 26. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 27. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 21-27, proceed to Step 30. Do NOT perform Steps 28-29. If you did NOT perform Steps 21-27, proceed to Step 28. 28. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 29. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 30. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 31. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 32. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 21-27 earlier, proceed to the next IMPORTANT statement prior to Step 35. Do not perform Steps 33-34. If you did NOT perform Steps 21-27 earlier proceed to Step 33. 33. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. 34. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 35. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 36. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 37. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 38. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8162 39. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor. 40. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud. Tighten Tighten the bolt to 9 Nm (80 lb in). 41. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time. 42. Lower the vehicle. 43. Install the upper starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 44. Raise the vehicle. 45. Tighten the lower starter bolt. Tighten Tighten the bolt to 90 Nm (66 lb ft). 46. Install a new oil filter. 47. Lower the vehicle. 48. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 49. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8163 50. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 51. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 52. Connect the electrical connector to the sensor in the air cleaner outlet duct. 53. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 54. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must he used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 55. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 56. Check the engine oil level and add as necessary. 1999-2001 J-Car - Cavalier/Sunfire with 2.4L Engine (VIN Code T) 1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body. 2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct. 3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing. 4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body. 5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8164 6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the lo~ation marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 11. Using an appropriate crimping took, install one end of the butt connector, included in the harness kit, on the purple wire. 12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8165 Important The-push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. Important The terminals located on the starter motor solenoid can be accessed through the opening between the runners in the intake manifold. It is not necessary to remove the starter motor to access the terminals on the 1999-2001 models. 15. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 16. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 24 and remove the nut. Do NOT perform Steps 17-23 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 22. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 17-23 proceed to Step 26. Do NOT perform Steps 24-25. If you did NOT perform Steps 17-23, proceed to Step 24. 24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 26. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness arid the service harness kit. 27. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8166 Important: If you performed Steps 17-23 earlier proceed to the next IMPORTANT statement prior to Step 31. Do not perform Steps 29-30. If you did NOT perform Steps 17-23 earlier, proceed to Step 29. 29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Important: Because access to the "S" terminal and the "B" terminal on the starter solenoid is limited, it may not be possible to use a torque wrench when tightening the terminal attaching nuts in upcoming Steps 30 and 34. If your torque wrench cannot be used because of insufficient clearance, it is acceptable to tighten the nuts "securely" using regular hand tools. 30. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 34. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 35. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the long bolts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8167 (1) that attach the starter motor end cap to the starter housing. 36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter. Tighten ^ Tighten the nut to 18 Nm (13 lb ft). ^ Tighten the long bolt to 9 Nm (80 lb in). 37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator. 38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator. 39. Install the air cleaner outlet resonator on the throttle body. Tighten Tighten the clamp to 5 Nm (44 lb in). 40. Connect the air cleaner outlet duct to the air cleaner housing. Tighten Tighten the clamp to 5 Nm (44 lb in). 41. Connect the electrical connector to the sensor in the air cleaner outlet duct. 42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten Tighten the bolts to 10 Nm (89 lb in). 43. Reinstall the negative battery cable to the battery. Tighten Tighten the bolt to 16 Nm (12 lb ft). Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 44. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4) 1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8168 1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut. 2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled. 3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled. 4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material. 5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it. 6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire. 7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole. 8. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten Tighten the bolt to 10 Nm (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8169 Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step. 9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness. 10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal. 11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid. ^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition. ^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding. 12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal. 13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid. 14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire. 15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit. 16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire. 17. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire. 18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you have just completed Steps 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19. 19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal. 20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal. 21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit. 22. Using an appropriate crimping tool, install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly. 23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection. Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8170 24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap. 25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut. Tighten Tighten the nut to 2.5 Nm (22 lb in). Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable. 26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid. 27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal. 28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal. 29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut. Tighten Tighten the nut to 11 Nm (97 lb in). 30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing. 31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter. Tighten Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in). 32. Reinstall the negative battery cable to the battery. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8171 Tighten the bolt to 16 Nm (12 lb ft). Important Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition. 33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times. ^ If the starter cranks the engine 6 times in a row, proceed to the next step. ^ If the starter will NOT crank the engine, skip to Procedure A for J Car Cavalier/Sunfire. 1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine) 1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines) 1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel. 2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel. 3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column. 4. Disconnect the yellow connectors. 5. If equipped, remove the tilt column lever. 6. Remove the three screws attaching the lower steering column cover and remove the cover. 7. Remove the upper steering column cover. 8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1). 9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch. 10. Connect the electrical connectors to the new ignition switch. Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used: ^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction. ^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw. 11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8172 Tighten the screws to 4 Nm (35 lb in). 12. Install the upper steering column cover. 13. Install the lower steering column cover and attaching screws. Tighten Tighten the screws to 4 Nm (35 lb in). 14. If equipped, install a new tilt lever. 15. Connect the two yellow SIR connectors at the base of the steering column. 16. Install the CPA in each connector and clip the connector(s) to the I/P brace. 17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 18. Install the AIR BAG fuse and install the fuse panel cover. 19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8173 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 04002 > Feb > 04 > Recall - Ignition Circuit Defect > Page 8174 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8180 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8181 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8182 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8183 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8184 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8185 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8186 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8187 Alignment: Technical Service Bulletins Alignment - Latest Available Specifications File In Section: 3 - Steering/Suspension Bulletin No.: 83-31-09 Date: October, 1998 INFORMATION Subject: Alignment Specifications Models: 1998-99 Passenger Cars and Trucks This bulletin is being issued to communicate, in chart form, the final 1998 and the initial 1999 model year vehicle alignment specifications. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8188 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8189 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8190 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8191 Specifications noted in these charts are the latest available and supersede any that have been previously published. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications Alignment: Specifications Vehicle Ride (Trim) Height Specifications J And K Measurements Model: 2JB37/2JB69 Suspension: FE1/FE2 Tire Size: P/195/70R14 Z: 12 mm (15/32 in) J: 233 mm (9.17 in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 8194 K: 240 mm (9.45 in) Model: 2JB37/2JB69 Suspension: FE1/FE2 Tire Size: P/195/65R15 Z: 6 mm (16/64 in) J: 233 mm (9.17 in) K: 240 mm (9.45 in) Model: 2JB67 Suspension: FE1/FE2 Tire Size: P/195/65R15 Z: 6 mm (16/64 in) J: 233 mm (9.17 in) K: 240 mm (9.45 in) All measurements taken with a full fuel tank. Measurements for J, K, and Z all have +/- 10 mm (3/8 in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 8195 Alignment: Specifications Alignment Specifications Wheel Alignment Specifications Front Caster: Alignment Specification ....................................................................................................................... ............................................................... 1.45° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Front Camber: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Individual Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.12° Sum Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.25° Cross Camber: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Cross Caster: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 1.00° Rear Camber: Alignment Specification ....................................................................................................................... .............................................................. -0.40° Tolerance ................................................................... ....................................................................................................................................... ± 0.75° Rear Sum Toe: Alignment Specification ....................................................................................................................... ............................................................... 0.20° Tolerance ................................................................... ....................................................................................................................................... ± 0.30° Rear Thrust Angle: Alignment Specification ....................................................................................................................... ............................................................... 0.00° Tolerance ................................................................... ....................................................................................................................................... ± 0.25° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, the control arms, the suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and no other loading or items in the trunk or passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8198 Alignment: Description and Operation Caster Description The caster is the tilting of the front steering axis (at the top) (1) either forward or backward from the vertical. A backward tilt is positive (+) and a forward tilt is negative (-). The caster influences directional control of the steering but does not affect the tire wear. The caster is affected by vehicle height, therefore it is important to keep the body at the designed height. Overloading the vehicle, or a weak or sagging rear spring, will affect the caster. When the rear of the vehicle is lower than the designed trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than the designated trim height, the front suspension moves to a less positive caster. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8199 Alignment: Description and Operation Camber Description The camber is the tilting of the front wheels from the vertical (1) when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. The camber setting will influence the directional control and the tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8200 Alignment: Description and Operation Toe Description The toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, the toe is positive (+). When the wheels are turned out, the toe is negative (-). The actual amount of toe is nominally only a fraction of a degree. The purpose of the toe is to ensure that the wheels roll parallel. The toe also serves to offset the small deflections of the wheel support system that occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, the wheels tend to roll parallel on the road when the vehicle is moving. The toe affects tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8201 Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, the control arms, the suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and no other loading or items in the trunk or passenger compartment. Caster Description The caster is the tilting of the front steering axis (at the top) (1) either forward or backward from the vertical. A backward tilt is positive (+) and a forward tilt is negative (-). The caster influences directional control of the steering but does not affect the tire wear. The caster is affected by vehicle height, therefore it is important to keep the body at the designed height. Overloading the vehicle, or a weak or sagging rear spring, will affect the caster. When the rear of the vehicle is lower than the designed trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than the designated trim height, the front suspension moves to a less positive caster. Camber Description The camber is the tilting of the front wheels from the vertical (1) when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. The camber setting will influence the directional control and the tire wear. Toe Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8202 The toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, the toe is positive (+). When the wheels are turned out, the toe is negative (-). The actual amount of toe is nominally only a fraction of a degree. The purpose of the toe is to ensure that the wheels roll parallel. The toe also serves to offset the small deflections of the wheel support system that occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, the wheels tend to roll parallel on the road when the vehicle is moving. The toe affects tire wear. Thrust Angles Description The front wheels aim or steer the vehicle, but the rear wheels control the tracking. This tracking action is relative to thrust angle. Thrust angle (2) is defined as the path that the rear wheels will take. Ideally, the thrust angle is geometrically aligned with the body centerline (1). Lead/Pull Description Lead/Pull is the deviation of the vehicle from a straight path, on a level road with no pressure on the steering wheel. Lead/Pull is generally caused by the following conditions: ^ A misconstructed tire. ^ An uneven brake adjustment. ^ A misaligned wheel. The way in which a tire is built can produce lead in a vehicle. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The RADIAL TIRE LEAD/PULL CORRECTION chart should be used to make sure that the front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead. Torque Steer Description Some degree of torque steer to the right may normally be experienced during a heavy throttle application on some front wheel drive vehicles which do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and an associated difference in an axle angle. Vehicles with intermediate shaft assembly have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Description > Page 8203 ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front for a difference in brand, construction or size. If the tires appear similar, change the front tires side to side and re-set the vehicle. Tire and wheel assemblies have the most significant effect on the torque steer correction. ^ A large difference in the right and left front tire pressure. ^ Any looseness in the control arm bushings, the tie rod assemblies, or the steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead deceleration. ^ A high front trim height which would increase the drive angle axle. ^ A binding or tight drive axle joint. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (15 and 30 mph). ^ An incorrect, worn or loose engine mounts causes adverse drive axle angles. ^ An unequal engine/transmission height from the left side to the right side of the vehicle. Determine the measuring points. Replace the engine/transmission mount if the difference from side to side is more than 6 mm (17/64 in). Do not shim the engine mounts. This may cause other symptoms. ^ On occasion, the side to side trim height differences may be the result of an inoperative stabilizer shaft. Disconnect the stabilizer links. Measure the trim heights again after the vehicle has been settled, driven a short distance. Replace the stabilizer shaft, if the side to side difference is corrected. Do not change the stabilizer shaft however, if there is no change in the trim height. A trim height difference of more than 6 mm (17/64 in), indicates a bent stabilizer shaft, attaching links or a suspension component that may need replacement. The following conditions affect the vehicle handling and/or a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ An incorrect front-wheel alignment or a rear-wheel alignment condition would cause the vehicle to track incorrectly. A difference in the front wheel to the rear wheel measurement. compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or other condition. The front-wheel caster should be equal or within specifications and the camber may be biased slightly in-order to offset a lead condition. ^ Suspension support misalignment. Refer to BODY AND FRAME for measurement points in order to determine proper underbody alignment. Front steering damage such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering Alignment: Testing and Inspection Hard Steering Hard Steering - Part 1 Of 2 Hard Steering - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8206 Alignment: Testing and Inspection Memory Steer Memory Steer - Part 1 Of 2 Memory Steer - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8207 Alignment: Testing and Inspection Torque Steer Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and the associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required in order to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: ^ A large difference in the right and the left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front tires for a difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. The tire and the wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joints. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (14 and 30 mph) ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal engine/transmission height from the left side to the right side of the vehicle. If a difference from side to side is more than 6 mm (17/64 in) , change the trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified Z heights. Replace the mounts. Do not shim the engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. In order to check this, disconnect the stabilizer links and re-measure the trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in the trim height, do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 in), indicates a possible bent stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect the vehicle handling and/or effect a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to track incorrectly. A difference in the front wheel to rear wheel measurement compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or an other condition. Front-wheel caster should be equal or within the specifications and the camber may be biased slightly in order to offset a lead condition. ^ Suspension support misalignment. Refer to UNDERBODY, which lists measurement points in order to determine proper underbody alignment. ^ Front suspension damage, such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8208 Vehicle Leads/Pulls Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8209 Alignment: Testing and Inspection Hard Steering - Part 1 Of 2 Hard Steering - Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8210 Memory Steer - Part 1 Of 2 Memory Steer - Part 2 Of 2 Torque Steer Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and the associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing start or at lower speeds. A simple measurement in order to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required in order to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause the torque steer to be more apparent on a particular vehicle: ^ A large difference in the right and the left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect the front tires for a difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. The tire and the wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joints. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (14 and 30 mph) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8211 ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal engine/transmission height from the left side to the right side of the vehicle. If a difference from side to side is more than 6 mm (17/64 in) , change the trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified Z heights. Replace the mounts. Do not shim the engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. In order to check this, disconnect the stabilizer links and re-measure the trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in the trim height, do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 in), indicates a possible bent stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect the vehicle handling and/or effect a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to track incorrectly. A difference in the front wheel to rear wheel measurement compared side to side may indicate a dog track condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or an other condition. Front-wheel caster should be equal or within the specifications and the camber may be biased slightly in order to offset a lead condition. ^ Suspension support misalignment. Refer to UNDERBODY, which lists measurement points in order to determine proper underbody alignment. ^ Front suspension damage, such as a bent strut. Vehicle Leads/Pulls Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8212 Wander Or Poor Steering Stability Dog Tracking Body Leans Or Sways In Corners Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8213 Suspension Bottoms Noisy Front Suspension Abnormal Or Excessive Tire Wear - Part 1 Of 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > System Diagnosis > Hard Steering > Page 8214 Abnormal Or Excessive Tire Wear - Part 2 Of 2 Wheel Bearings Diagnosis Wheel Bearings Diagnosis CAUTION: front wheel drive vehicles, drive wheel spin should be limited to 35 mph as indicated on the speedometer. This limit is necessary because the speedometer only Indicates one-half of the actual wheel speed when one drive wheel is spinning and the other drive wheel Is stopped. Unless care is taken In limiting drive wheel spin, the spinning wheel can reach excessive speeds. This can result in possible tire disintegration or differential failure, which could cause serious personal injury or extensive vehicle damage. Wheel Tramp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection Alignment: Service and Repair Preliminary Inspection PRELIMINARY INSPECTIONS The steering and the ride complaints are not always the result of improper alignment. Another possibility is tire lead due to worn or improperly manufactured tires. The lead is the vehicle's deviation from a straight path on a level road without pressure on the steering wheel. Refer to VEHICLE LEADS/PULLS in SUSPENSION GENERAL DIAGNOSIS for the procedure to determine if the vehicle had a lead problem. Before making any adjustment affecting wheel alignment, make the following inspections in order to ensure correct the alignment readings and the alignment adjustments. Inspect 1. Inspect all the tires for the proper inflation pressures. Also check that the tires have about the same tread wear. 2. Inspect the hub and bearing assemblies for excessive wear. Correct as necessary. 3. Inspect the ball joints and the tie rod ends; if they are loose, correct them before adjusting. 4. Inspect the vehicle trim height. If it is out of limits and a correction is to be made, do so before adjusting the alignment. Refer to TRIM HEIGHT SPECIFICATIONS in SUSPENSION GENERAL DIAGNOSIS. 5. Inspect the strut dampeners for proper operation. 6. Inspect the control arms for loose bushings. 7. Inspect the stabilizer shaft for loose or missing parts. 8. Inspect the suspension and the steering components for damage and replace the parts as necessary. Consideration must be given to excess loads, such as tool boxes, sample cases, etc. If the items are normally carried in the vehicle, the items should remain in the vehicle during alignment adjustments. Loads such as these should be centered in the vehicle whenever possible to minimize their effects. Consideration should also be given to the condition of the equipment being used in order to adjust the alignment. Be sure to follow the equipment manufacturer's instructions. Regardless of the equipment used to adjust the alignment, the vehicle must be on a level surface, both fore-and-aft and sideways. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8217 Alignment: Service and Repair Ride/Trim Height Measurement and Adjustment 1. Prior to measuring the vehicle trim height, prepare the vehicle as follows: 2. Ensure that the following conditions exist: 2.1. The fuel gage reads full. 2.2. The spare tire and the tools are properly located. 2.3. The vehicle is free of the ice, the snow and the mud accumulations. 3. Set the front and the rear tire pressure to within plus or minus 20 kPa (3 psi) of the recommended pressure shown on the tire placard. If two load conditions are shown on the placard, use the lower load condition. 4. Close the engine compartment hood and all of the doors. 5. Up to 7 kg (15.5 lb) may be left in the trunk if it is located approximately on the vehicle centerline. Remove the items necessary in order to meet this requirement. 6. Measure the vehicle trim height as follows: ^ Z and J Dimensions: Lift the front bumper of the vehicle up approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle settle. Repeat twice for a total of 3 times. Measure Z and J dimensions. Push the front bumper down approximately 38.0 mm (1 1/2 in). Gently repeat twice for a total of 3 times. Measure Z and J dimensions. True heights are the average of the high and low measurements. ^ K dimension: Lift the rear bumper of the vehicle up approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle settle. Repeat twice for a total of 3 times. Measure K dimension. Push the rear bumper down approximately 38.0 mm (1 1/2 in). Gently remove your hands and let the vehicle rise on its own. Repeat twice for a total of 3 times. Measure K dimension. True heights are the average of the high Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8218 and low measurements. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8219 Alignment: Service and Repair Front Wheel Alignment Measuring Front Alignment Angles MEASURING FRONT ALIGNMENT ANGLES Important: ^ Install the alignment equipment following the manufacturer's instructions. ^ Jounce the front and rear bumpers three times to normalize the suspension prior to measuring the angles. ^ Measure the alignment angles and record the readings. If adjustments are necessary, make them in the following order: 1. Camber. 2. Toe. Front Caster Adjustment The caster is not adjustable. If the caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace the parts as necessary. Refer to BODY AND FRAME for measurement points in order to determine the proper underbody alignment. Front Camber Adjustment Important: When the camber adjustment is necessary, refer to STRUT AND KNUCKLE SCRIBING for instructions on modifying the front strut. 1. Loosen both of the strut to knuckle nuts in order to allow slight movement. 2. Adjust the camber to specification by moving the top of the wheel in or out. Refer to WHEEL ALIGNMENT SPECIFICATIONS. 3. Tighten the strut to the knuckle nuts. Tighten Tighten the strut to the knuckle nuts to 180 Nm (133 ft. lbs.). Front Toe Adjustment 1. Be sure the steering wheel is set in a straight ahead position within +/- 5°. 2. Loosen the clamp bolt (4). 3. Adjust the toe to specification by turning the adjuster (3). Tighten Tighten the jam nut to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8220 Refer to FASTENER TIGHTENING SPECIFICATIONS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8221 Alignment: Service and Repair Rear Wheel Alignment MEASURING REAR ALIGNMENT ANGLES After the front wheel alignment has been completed, the rear alignment angles should be checked if there is excessive rear tire wear or the wheels do not track properly. The rear wheels should be parallel to and the same distance from the vehicle's centerline. REAR WHEEL ALIGNMENT Rear wheel alignment is not adjustable. If the camber and toe angles are not within the specifications, inspect for underbody or rear suspension damage. Refer to BODY AND FRAME to determine proper underbody alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Maximum): First ...................................................................................................................................................... ................................................ 65 N.m (50 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Minimum): First ...................................................................................................................................................... ................................................ 55 N.m (41 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Caliper to Knuckle Bolts ...................................................................................................................... ................................................... 51 N.m (38 ft. lbs.) Hub and Bearing Assembly to Steering Knuckle Bolts ........................................................................................................................... 95 N.m (70 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 8226 Front Steering Knuckle: Testing and Inspection 1. Check the ball stud tightness in the steering knuckle boss. 1.1. Shake the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. 1.2. Check the castellated nut fastener tightening specifications is an alternative method of inspecting for wear. A loose nut can indicate a bent stud or an opened-up hole in the knuckle boss. 2. Replace worn or damaged ball joints and knuckles. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions Front Steering Knuckle: Service and Repair Repair Instructions REMOVAL PROCEDURE ^ Tools Required: J 38892 Ball Joint Separator - J 28733-B Front Hub Spindle Remover 1. Remove the hub and bearing assembly (1). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 2. Remove the bolts (6) attaching the steering knuckle (3) to the strut (1). 3. Remove the cotter pin (1). 4. Remove the nut (4) from the ball joint (3). 5. Use the J 38892 in order to separate the ball joint (3) from the knuckle (2). 6. Remove the knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8229 1. Install the steering knuckle (2) to the ball joint (3). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the ball joint nut (4). Tighten Tighten the ball joint nut to 55 Nm (41 ft. lbs.) (minimum) and 65 Nm (50 ft. lbs.) (maximum). 3. Install the cotter pin (1). 4. Install the steering knuckle (3) into the strut (1). 5. Install the steering knuckle to strut assembly bolts (6). Tighten Tighten the nuts (2) to 180 Nm (133 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8230 6. Install the hub and bearing assembly (1) onto the knuckle (2). 7. Install the hub and bearing assembly bolts (1). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 8. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8231 Front Steering Knuckle: Service and Repair Strut and Knuckle Scribing SCRIBING PROCEDURE 1. Scribe the knuckle along the lower outboard strut radius (shown by the dotted line). Use a sharp tool. 2. Scribe the strut flange on the inboard side along the curve of the knuckle (shown by the dotted line). 3. Make a scribe mark across the strut/knuckle interface. 4. Match the marks to the components during reassembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications GM Power Steering Fluid (GM P/N 1052884 - 1 pint or 1050017 - 1 quart, or equivalent). In cold climates use (GM P/N 12345866 - one pint, GM P/N 12345867 - one quart, or equivalent). NOTE: The system should be flushed and bled prior to switching fluid types. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Inlet Line Fittings ........................................................................................................................................................... 27 N.m (20 ft. lbs.) Power Steering Outlet Hose Assembly Fittings ....................................................................................................................................... 27 N.m (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Power Steering Line/Hose: Service and Repair Gear Inlet Hose Power Steering Restrictor Valve And Hose Routing Power Steering Line And Hose Routing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 8244 Power Steering Line And Hose Routing Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 8245 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. Tighten ^ Gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Refer to BLEEDING THE POWER STEERING SYSTEM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose > Page 8246 Power Steering Line/Hose: Service and Repair Gear Outlet Hose Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten ^ Outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten ^ Hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill with fluid and bleed air from power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM. Inspect ^ For leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power Steering Pump Seal > Component Information > Service and Repair Power Steering Pump Seal: Service and Repair Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the pinion shaft and on the drive shaft of the pump. When a leak occurs in this area, always replace the seal after inspecting and thoroughly cleaning the sealing surface. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by smoothing with crocus cloth first. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8260 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8261 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8262 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8263 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection For diagnosis of the system, Refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation Technical Service Bulletin # 02049 Date: 030101 Recall - Steering Gear Lower Pinion Bearing Separation File In Section: Product Recalls Bulletin No.: 02049 Date: January, 2003 PRODUCT SAFETY RECALL SUBJECT: 02049 - POWER STEERING GEAR LOWER PINION BEARING SEPARATION MODELS: 1996-1998 CHEVROLET CAVALIER 1996 CHEVROLET LUMINA APV 1997-1998 CHEVROLET VENTURE 1996-1998 PONTIAC SUNFIRE, TRANS SPORT 1997-1998 PONTIAC GRAND PRIX 1996-1998 OLDSMOBILE SILHOUETTE CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Pontiac Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles. Some of these vehicles have a condition where the lower pinion bearing in the power steering gear may separate. Most reports indicate the driver experienced an intermittent loss of power steering assist when making left turns, usually at low speeds. Power assist is normal in right hand turns. When trying to turn left, some drivers could experience higher resistance or, in a few cases, assist towards the right. If this happens while the vehicle is moving, a crash could result. CORRECTION Dealers are to inspect the condition of the lower pinion bearing and replace the lower pinion bearing, or in a few cases, replace the rack and pinion steering gear assembly. VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8275 Involved are certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of January 13, 2003. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8276 CSO = Customer Special Order. SPECIAL TOOL Beginning the week of December 23, 2002, each dealer will be shipped a Power Steering Pinion Bearing Replacer, J44714-A, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657). RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CUSTOMER REIMBURSEMENT Customer requests for reimbursement of previously paid repairs to replace the power steering gear lower pinion bearing or steering gear due to lower pinion bearing separation are to be submitted by January 31, 2004 (this time limit may be longer depending on the law in your state/province/country). All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following. - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8277 the repair. Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8278 Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Information Important If a vehicle has had the power steering gear lower pinion bearing or steering gear replaced prior to this recall, the applicable service procedures shown will still need to be performed on the vehicle. 1996 Lumina APV, Trans Sport, and Silhouette Lower Pinion Bearing Inspection (Includes Steering Gear Replacement, If Required) Because of limited access in this vehicle, the pinion bearing can only be inspected after the steering gear has been removed from the vehicle. For additional information on steering gear removal and bleeding the system, see the steering section of the appropriate service manual. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Remove both wheel and tire assemblies. 6. Remove the cotter pins and nuts from both outer tie rod ends. 7. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8279 8. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 11. Disconnect the pressure and return lines from the steering gear. 12. Remove the two bolts that attach the steering gear to the engine cradle 13. Separate the intermediate steering shaft cover (boot) from the steering gear. 14. Remove the steering gear from the vehicle. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 15. On a suitable work surface, remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to step 31 and replace the complete steering gear assembly. 16. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 17. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8280 18. Remove the lower retaining snap ring (1), see Figure 3. 19. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 20. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8281 21. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 22. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. 23. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 24. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 25. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. Lightly tap with a hammer until the bearing is seated in the housing. 26. Install a new snap ring. When properly installed, the large lug (1) on the snap ring must be on the right side as shown in Figure 9. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8282 27. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft) 28. Install a new dust cap (2) to the steering gear housing. 29. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 30. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 31. If installing a new steering gear, transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 32. If installing a new steering gear, remove the tie rod ends from the old steering gear. 33. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 34. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 30 Nm (22 lb ft) plus 120 degrees (or 2 flats of the nut). 35. Install the steering gear to the engine cradle in the vehicle. 36. Install the two bolts attaching the steering gear to the cradle. Tighten to 80 Nm (59 lb ft). 37. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 38. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 39. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 165 Nm (122 lb ft). 40. Reposition the intermediate steering shaft cover (boot) and attach to the steering gear. 41. Connect the outer tie rod ends to the steering knuckles and install the nuts. Tighten the nuts to 10 Nm (88 lb in) and then tighten the nuts an additional 180 degrees (1/2 turn). If necessary, rotate (tighten) the nuts to align the hole and install the cotter pins. 42. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 43. Lower the vehicle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8283 44. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 45. Install the driver's side insulator panel under the IP. 46. Add power steering fluid as necessary and bleed the system 47. Check alignment and set toe-in as necessary. 48. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 6. Lower the rear of the engine cradle as necessary to access steering gear. 7. Remove the left and right side stabilizer bar links from the lower control arms. 8. Reposition the stabilizer bar to improve access to the steering gear. 9. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 10. Remove the two bolts that attach the steering gear to the engine cradle. 11. Remove the steering gear from the cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 12. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 13. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 14. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 15. Remove the lower remaining snap ring (1), see Figure 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8284 16. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 17. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 18. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6 Finger tighten the forcing screw to push the puller legs against the bearing. 19. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 20. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 21. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 22. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 23. Install a new snap ring, Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 24. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 25. Install a new dust cap (2) to the steering gear housing. 26. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 27. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 28. Reinstall the steering gear in the engine cradle mounting brackets. 29. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 30. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 31. Reposition the stabilizer bar. 32. Install the left and right side stabilizer bar links to the lower control arms. Tighten the bolts to 23 Nm (17 lb ft). 33. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 34. Install the two rear engine cradle attaching bolts. Tighten to 165 Nm (122 lb ft). 35. Lower the vehicle 36. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 37. Install the driver's side insulator panel under the IP. 38. Check the power steering fluid and add if necessary. 39. Check alignment and set toe-in as necessary. 40. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8285 2. Loosen the outer tie rod adjuster nuts. 3. Remove both wheel and tire assemblies. 4. Remove the nuts that attach the tie rod ends to the steering knuckle. 5. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 6. Separate the intermediate steering shaft cover (boot) from the steering gear. 7. Remove the steering gear from the vehicle. 8. Transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 9. Remove the tie rod ends from the old steering gear. 10. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 11. Install the tie rod end on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 12. Install the new steering gear in the vehicle. 13. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 14. Install the steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 16. Install the heat shield to the steering gear and install the attaching bolts. Tighten the bolts to 14 Nm (124 lb in). 17. Reposition the stabilizer bar. 18. Install the left and right side stabilizer bar links to the lower control arm. Tighten the bolts to 23 Nm (17 lb ft). 19. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 20. Install the two rear engine cradle attaching bolts. Tighten the bolts to 165 Nm (122 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Install both wheel and tire assemblies. 23. Lower the vehicle. 24. From inside the vehicle, connect the intermediate steering shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 25. Install the driver's side insulator panel under the IP. 26. Add power steering fluid and bleed the system. 27. Check alignment and set toe-in as necessary. 28. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8286 Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 3. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 4. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 5. Remove the left and right side stabilizer bar links from the lower control arms. 6. Reposition the stabilizer bar as necessary to improve access to the steering gear. 7. Remove the two bolts that attach the steering gear to the engine cradle. 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the steering gear from the engine cradle mounting brackets and reposition to access the adjuster plug lock nut and the adjuster plug. Do not remove the plug. 11. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 12. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 13. Remove the lower retaining snap ring (1), Figure 3. Important Placement of a block of wood between the steering gear housing and the transmission case will help to support the steering gear in the next step. 14. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 15. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 16. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 17. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 18. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 19. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 20. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 21. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8287 Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 22. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 23. Install a new dust cap (2) to the steering gear housing. 24. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 25. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 26. Install the steering gear in the engine cradle mounting brackets. 27. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 28. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 180 Nm (133 lb ft). 29. Connect the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 48 Nm (35 lb ft). 30. Reposition the stabilizer bar. 31. Install the left and right side stabilizer bar links to the lower control arm. Tighten to 23 Nm (17 lb ft). 32. Lower the vehicle. 33. Check the power steering fluid and add if necessary. 34. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Remove the bolt and separate the intermediate steering shaft from the steering gear. 2. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 3. Remove the left and right side stabilizer bar links from the lower control arms. 4. Reposition the stabilizer bar as necessary to improve access to the steering gear. 5. Remove the two bolts that attach the steering gear to the engine cradle. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Loosen the outer tie rod end adjuster nuts. 8. Remove both wheel and tire assemblies. 9. Remove the nuts that attach the tie rod ends to the steering knuckles. 10. Using J-24319-B (outer tie rod end puller) or equivalent, separate the tie rod ends from the knuckles. 11. Disconnect the pressure and return lines from the steering gear. 12. On GT and GTP models, disconnect the electrical connector from the steering gear. 13. Remove the steering gear from the vehicle. 14. Remove the tie rod ends from the old steering gear. 15. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 16. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8288 17. Install the new steering gear in the engine cradle mounting brackets. 18. On GT and GTP models, connect the electrical connector for the steering gear. 19. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 20. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Raise the rear of the engine cradle and install the two rear attaching bolts. Tighten to 180 Nm (133 lb ft). 23. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten to 48 Nm (35 lb ft). 24. Reposition the stabilizer bar. 25. Install the left and right side stabilizer bar links to the lower control arms. Tighten to 23 Nm (17 lb ft). 26. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 27. Lower the vehicle. 28. Add power steering fluid and bleed the system. 29. Check the alignment and set toe-in as necessary. 30. Install the GM Recall Identification Label Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. 3. Remove the two bolts attaching the steering gear to the engine frame (cradle). 4. Release the brake pipe from the retainers at three locations on the engine cradle. 5. Remove the steering gear from the engine cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 6. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicle. 7. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8289 8. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 9. Remove the lower retaining snap ring (1), see Figure 3. 10. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 11. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 12. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 13. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 14. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 15. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 16. Place the bearing installer (1) JA4714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use extension JA4714-3 included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 17. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 18. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 19. Install a new dust cap (2) to the steering gear housing. 20. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 21. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 22. Reinstall the steering gear in the engine cradle mounting brackets. 23. Reattach the brake pipe to the retainers on the engine cradle. 24. Install the two bolts attaching the steering gear to the cradle. Tighten to 120 Nm (88 lb ft). 25. Lower the vehicle. 26. Check the power steering fluid level and add if necessary. 27. Install the GM Recall Identification Label. Steering Gear Replacement, If Required 1. Remove both wheel and tire assemblies. 2. Remove the nuts that attach the tie rod ends to the steering knuckle. 3. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 4. Support the rear of the engine frame (cradle) and remove the six rear attaching bolts. 5. Loosen the front cradle to body attaching bolts. Do not remove the bolts. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8290 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Remove the steering gear from the vehicle. 10. If necessary, transfer the mounting grommet(s) and bushing(s) from the old steering gear to the new steering gear. Note: The labor time allowance includes the time needed for transferring these parts. 11. Remove the tie rod ends from the old steering gear. 12. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 13. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 14. Install the new steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 120 Nm (88 lb ft). 16. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 17. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 18. Install the six rear engine cradle bolts. Tighten to 110 Nm (81 lb ft). 19. Tighten the front engine cradle to body bolts to 110 Nm (81 lb ft). 20. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 22 Nm (16 lb ft). 21. Reattach the brake pipe to the retainers on the engine cradle. 22. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 45 Nm (33 lb ft). 23. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 24. Lower the vehicle 25. Add power steering fluid and bleed the system. 26. Check the alignment and set toe-in as necessary. 27. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8291 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8292 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > NHTSA02V286000 > Nov > 02 > Recall 02V286000: Steering Rack Defect Steering Gear: Recalls Recall 02V286000: Steering Rack Defect DEFECT: Certain passenger vehicles and minivans have lower pinion bearings in the power steering rack and pinion assembly in which the retainer tabs were not crimped properly. These and some other retainers could fail and permit the ball bearings to escape. If this occurs, the pinion shaft can be forced upward during left turns and back down as the steering wheel is moved back and to the right. If the pinion shaft moves further, the driver will need to exert more effort to turn the steering wheel, similar to a vehicle without power assisted steering. If the pinion shaft moves even further, the driver will require much higher effort to turn left and may not be able to turn the wheel as much as intended. With the maximum pinion shaft movement, which requires internal gear component damage, the driver can encounter high resistance to turning left, followed by unintended power assist to the right. In any of these conditions, a crash could occur. REMEDY: Dealers will install a new lower pinion bearing unless inspection of the existing bearing indicates that replacement of the gear assembly is necessary. The manufacturer has reported that owner notification began Jan. 17, 2003. Owners should contact Chevrolet at 1-800-222-1020, Pontiac at 1-8000-762-2737, or Oldsmobile at 1-800-442-6537. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation Technical Service Bulletin # 02049 Date: 030101 Recall - Steering Gear Lower Pinion Bearing Separation File In Section: Product Recalls Bulletin No.: 02049 Date: January, 2003 PRODUCT SAFETY RECALL SUBJECT: 02049 - POWER STEERING GEAR LOWER PINION BEARING SEPARATION MODELS: 1996-1998 CHEVROLET CAVALIER 1996 CHEVROLET LUMINA APV 1997-1998 CHEVROLET VENTURE 1996-1998 PONTIAC SUNFIRE, TRANS SPORT 1997-1998 PONTIAC GRAND PRIX 1996-1998 OLDSMOBILE SILHOUETTE CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Pontiac Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles. Some of these vehicles have a condition where the lower pinion bearing in the power steering gear may separate. Most reports indicate the driver experienced an intermittent loss of power steering assist when making left turns, usually at low speeds. Power assist is normal in right hand turns. When trying to turn left, some drivers could experience higher resistance or, in a few cases, assist towards the right. If this happens while the vehicle is moving, a crash could result. CORRECTION Dealers are to inspect the condition of the lower pinion bearing and replace the lower pinion bearing, or in a few cases, replace the rack and pinion steering gear assembly. VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8302 Involved are certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of January 13, 2003. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8303 CSO = Customer Special Order. SPECIAL TOOL Beginning the week of December 23, 2002, each dealer will be shipped a Power Steering Pinion Bearing Replacer, J44714-A, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657). RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CUSTOMER REIMBURSEMENT Customer requests for reimbursement of previously paid repairs to replace the power steering gear lower pinion bearing or steering gear due to lower pinion bearing separation are to be submitted by January 31, 2004 (this time limit may be longer depending on the law in your state/province/country). All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following. - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8304 the repair. Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8305 Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Information Important If a vehicle has had the power steering gear lower pinion bearing or steering gear replaced prior to this recall, the applicable service procedures shown will still need to be performed on the vehicle. 1996 Lumina APV, Trans Sport, and Silhouette Lower Pinion Bearing Inspection (Includes Steering Gear Replacement, If Required) Because of limited access in this vehicle, the pinion bearing can only be inspected after the steering gear has been removed from the vehicle. For additional information on steering gear removal and bleeding the system, see the steering section of the appropriate service manual. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Remove both wheel and tire assemblies. 6. Remove the cotter pins and nuts from both outer tie rod ends. 7. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8306 8. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 11. Disconnect the pressure and return lines from the steering gear. 12. Remove the two bolts that attach the steering gear to the engine cradle 13. Separate the intermediate steering shaft cover (boot) from the steering gear. 14. Remove the steering gear from the vehicle. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 15. On a suitable work surface, remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to step 31 and replace the complete steering gear assembly. 16. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 17. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8307 18. Remove the lower retaining snap ring (1), see Figure 3. 19. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 20. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8308 21. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 22. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. 23. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 24. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 25. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. Lightly tap with a hammer until the bearing is seated in the housing. 26. Install a new snap ring. When properly installed, the large lug (1) on the snap ring must be on the right side as shown in Figure 9. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8309 27. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft) 28. Install a new dust cap (2) to the steering gear housing. 29. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 30. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 31. If installing a new steering gear, transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 32. If installing a new steering gear, remove the tie rod ends from the old steering gear. 33. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 34. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 30 Nm (22 lb ft) plus 120 degrees (or 2 flats of the nut). 35. Install the steering gear to the engine cradle in the vehicle. 36. Install the two bolts attaching the steering gear to the cradle. Tighten to 80 Nm (59 lb ft). 37. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 38. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 39. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 165 Nm (122 lb ft). 40. Reposition the intermediate steering shaft cover (boot) and attach to the steering gear. 41. Connect the outer tie rod ends to the steering knuckles and install the nuts. Tighten the nuts to 10 Nm (88 lb in) and then tighten the nuts an additional 180 degrees (1/2 turn). If necessary, rotate (tighten) the nuts to align the hole and install the cotter pins. 42. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 43. Lower the vehicle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8310 44. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 45. Install the driver's side insulator panel under the IP. 46. Add power steering fluid as necessary and bleed the system 47. Check alignment and set toe-in as necessary. 48. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 6. Lower the rear of the engine cradle as necessary to access steering gear. 7. Remove the left and right side stabilizer bar links from the lower control arms. 8. Reposition the stabilizer bar to improve access to the steering gear. 9. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 10. Remove the two bolts that attach the steering gear to the engine cradle. 11. Remove the steering gear from the cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 12. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 13. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 14. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 15. Remove the lower remaining snap ring (1), see Figure 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8311 16. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 17. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 18. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6 Finger tighten the forcing screw to push the puller legs against the bearing. 19. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 20. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 21. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 22. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 23. Install a new snap ring, Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 24. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 25. Install a new dust cap (2) to the steering gear housing. 26. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 27. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 28. Reinstall the steering gear in the engine cradle mounting brackets. 29. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 30. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 31. Reposition the stabilizer bar. 32. Install the left and right side stabilizer bar links to the lower control arms. Tighten the bolts to 23 Nm (17 lb ft). 33. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 34. Install the two rear engine cradle attaching bolts. Tighten to 165 Nm (122 lb ft). 35. Lower the vehicle 36. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 37. Install the driver's side insulator panel under the IP. 38. Check the power steering fluid and add if necessary. 39. Check alignment and set toe-in as necessary. 40. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8312 2. Loosen the outer tie rod adjuster nuts. 3. Remove both wheel and tire assemblies. 4. Remove the nuts that attach the tie rod ends to the steering knuckle. 5. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 6. Separate the intermediate steering shaft cover (boot) from the steering gear. 7. Remove the steering gear from the vehicle. 8. Transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 9. Remove the tie rod ends from the old steering gear. 10. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 11. Install the tie rod end on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 12. Install the new steering gear in the vehicle. 13. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 14. Install the steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 16. Install the heat shield to the steering gear and install the attaching bolts. Tighten the bolts to 14 Nm (124 lb in). 17. Reposition the stabilizer bar. 18. Install the left and right side stabilizer bar links to the lower control arm. Tighten the bolts to 23 Nm (17 lb ft). 19. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 20. Install the two rear engine cradle attaching bolts. Tighten the bolts to 165 Nm (122 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Install both wheel and tire assemblies. 23. Lower the vehicle. 24. From inside the vehicle, connect the intermediate steering shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 25. Install the driver's side insulator panel under the IP. 26. Add power steering fluid and bleed the system. 27. Check alignment and set toe-in as necessary. 28. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8313 Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 3. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 4. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 5. Remove the left and right side stabilizer bar links from the lower control arms. 6. Reposition the stabilizer bar as necessary to improve access to the steering gear. 7. Remove the two bolts that attach the steering gear to the engine cradle. 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the steering gear from the engine cradle mounting brackets and reposition to access the adjuster plug lock nut and the adjuster plug. Do not remove the plug. 11. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 12. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 13. Remove the lower retaining snap ring (1), Figure 3. Important Placement of a block of wood between the steering gear housing and the transmission case will help to support the steering gear in the next step. 14. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 15. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 16. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 17. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 18. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 19. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 20. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 21. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8314 Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 22. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 23. Install a new dust cap (2) to the steering gear housing. 24. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 25. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 26. Install the steering gear in the engine cradle mounting brackets. 27. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 28. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 180 Nm (133 lb ft). 29. Connect the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 48 Nm (35 lb ft). 30. Reposition the stabilizer bar. 31. Install the left and right side stabilizer bar links to the lower control arm. Tighten to 23 Nm (17 lb ft). 32. Lower the vehicle. 33. Check the power steering fluid and add if necessary. 34. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Remove the bolt and separate the intermediate steering shaft from the steering gear. 2. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 3. Remove the left and right side stabilizer bar links from the lower control arms. 4. Reposition the stabilizer bar as necessary to improve access to the steering gear. 5. Remove the two bolts that attach the steering gear to the engine cradle. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Loosen the outer tie rod end adjuster nuts. 8. Remove both wheel and tire assemblies. 9. Remove the nuts that attach the tie rod ends to the steering knuckles. 10. Using J-24319-B (outer tie rod end puller) or equivalent, separate the tie rod ends from the knuckles. 11. Disconnect the pressure and return lines from the steering gear. 12. On GT and GTP models, disconnect the electrical connector from the steering gear. 13. Remove the steering gear from the vehicle. 14. Remove the tie rod ends from the old steering gear. 15. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 16. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8315 17. Install the new steering gear in the engine cradle mounting brackets. 18. On GT and GTP models, connect the electrical connector for the steering gear. 19. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 20. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Raise the rear of the engine cradle and install the two rear attaching bolts. Tighten to 180 Nm (133 lb ft). 23. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten to 48 Nm (35 lb ft). 24. Reposition the stabilizer bar. 25. Install the left and right side stabilizer bar links to the lower control arms. Tighten to 23 Nm (17 lb ft). 26. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 27. Lower the vehicle. 28. Add power steering fluid and bleed the system. 29. Check the alignment and set toe-in as necessary. 30. Install the GM Recall Identification Label Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. 3. Remove the two bolts attaching the steering gear to the engine frame (cradle). 4. Release the brake pipe from the retainers at three locations on the engine cradle. 5. Remove the steering gear from the engine cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 6. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicle. 7. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8316 8. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 9. Remove the lower retaining snap ring (1), see Figure 3. 10. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 11. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 12. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 13. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 14. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 15. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 16. Place the bearing installer (1) JA4714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use extension JA4714-3 included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 17. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 18. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 19. Install a new dust cap (2) to the steering gear housing. 20. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 21. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 22. Reinstall the steering gear in the engine cradle mounting brackets. 23. Reattach the brake pipe to the retainers on the engine cradle. 24. Install the two bolts attaching the steering gear to the cradle. Tighten to 120 Nm (88 lb ft). 25. Lower the vehicle. 26. Check the power steering fluid level and add if necessary. 27. Install the GM Recall Identification Label. Steering Gear Replacement, If Required 1. Remove both wheel and tire assemblies. 2. Remove the nuts that attach the tie rod ends to the steering knuckle. 3. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 4. Support the rear of the engine frame (cradle) and remove the six rear attaching bolts. 5. Loosen the front cradle to body attaching bolts. Do not remove the bolts. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8317 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Remove the steering gear from the vehicle. 10. If necessary, transfer the mounting grommet(s) and bushing(s) from the old steering gear to the new steering gear. Note: The labor time allowance includes the time needed for transferring these parts. 11. Remove the tie rod ends from the old steering gear. 12. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 13. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 14. Install the new steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 120 Nm (88 lb ft). 16. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 17. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 18. Install the six rear engine cradle bolts. Tighten to 110 Nm (81 lb ft). 19. Tighten the front engine cradle to body bolts to 110 Nm (81 lb ft). 20. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 22 Nm (16 lb ft). 21. Reattach the brake pipe to the retainers on the engine cradle. 22. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 45 Nm (33 lb ft). 23. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 24. Lower the vehicle 25. Add power steering fluid and bleed the system. 26. Check the alignment and set toe-in as necessary. 27. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8318 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8319 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > NHTSA02V286000 > Nov > 02 > Recall 02V286000: Steering Rack Defect Steering Gear: All Technical Service Bulletins Recall 02V286000: Steering Rack Defect DEFECT: Certain passenger vehicles and minivans have lower pinion bearings in the power steering rack and pinion assembly in which the retainer tabs were not crimped properly. These and some other retainers could fail and permit the ball bearings to escape. If this occurs, the pinion shaft can be forced upward during left turns and back down as the steering wheel is moved back and to the right. If the pinion shaft moves further, the driver will need to exert more effort to turn the steering wheel, similar to a vehicle without power assisted steering. If the pinion shaft moves even further, the driver will require much higher effort to turn left and may not be able to turn the wheel as much as intended. With the maximum pinion shaft movement, which requires internal gear component damage, the driver can encounter high resistance to turning left, followed by unintended power assist to the right. In any of these conditions, a crash could occur. REMEDY: Dealers will install a new lower pinion bearing unless inspection of the existing bearing indicates that replacement of the gear assembly is necessary. The manufacturer has reported that owner notification began Jan. 17, 2003. Owners should contact Chevrolet at 1-800-222-1020, Pontiac at 1-8000-762-2737, or Oldsmobile at 1-800-442-6537. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench Steering Gear: All Technical Service Bulletins Tools - Adjuster Locknut Wrench File In Section: 3 - Steering/Suspension Bulletin No.: 83-32-10 Date: November, 1998 INFORMATION Subject: Essential Tool J 43435 Adjuster Locknut Wrench Models: 1990-99 Passenger Cars and Trucks with Integral Power Steering A new essential tool, J 43435 Adjuster Locknut Wrench, has been sent to all GM Dealers. This tool should be used on all Integral power steering gears, both past and current models. The following procedure should be used In place of existing Service Manual procedures for Coupling Shield and Locknut Removal and Replacement. The correct adjustment procedure and use of the essential tools are critical to restore the vehicle "On Center" feel (See Figure 1). Important: Coupling shield retainer and locknut assembly replacement procedures require the following special tools: J 42882 Adjuster Nut Wrench J 43435 Adjuster Locknut Wrench Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench > Page 8328 (See Figure 2) Procedure 1. Place J 42882 over the end of the stub shaft. Place J 43435 over the end. J 43435 is reversible and can be used with both old and new style coupling shield retainers and locknuts. 2. Tighten the coupling shield retainer and locknut assembly after an adjustment or repair has been made to the power steering gear to the specified torque (See Figure 3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench Steering Gear: All Technical Service Bulletins Tools - Adjuster Locknut Wrench File In Section: 3 - Steering/Suspension Bulletin No.: 83-32-10 Date: November, 1998 INFORMATION Subject: Essential Tool J 43435 Adjuster Locknut Wrench Models: 1990-99 Passenger Cars and Trucks with Integral Power Steering A new essential tool, J 43435 Adjuster Locknut Wrench, has been sent to all GM Dealers. This tool should be used on all Integral power steering gears, both past and current models. The following procedure should be used In place of existing Service Manual procedures for Coupling Shield and Locknut Removal and Replacement. The correct adjustment procedure and use of the essential tools are critical to restore the vehicle "On Center" feel (See Figure 1). Important: Coupling shield retainer and locknut assembly replacement procedures require the following special tools: J 42882 Adjuster Nut Wrench J 43435 Adjuster Locknut Wrench Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench > Page 8334 (See Figure 2) Procedure 1. Place J 42882 over the end of the stub shaft. Place J 43435 over the end. J 43435 is reversible and can be used with both old and new style coupling shield retainers and locknuts. 2. Tighten the coupling shield retainer and locknut assembly after an adjustment or repair has been made to the power steering gear to the specified torque (See Figure 3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8335 Steering Gear: Specifications Hex Torque Prevailing Nut [Outer Tie Rod (1)]: First 10 N.m (84 inch lbs.) Final 210° Jam Nut (7) 68 N.m (50 ft. lbs.) Inner Tie Rod (12) 100 N.m (74 ft. lbs.) Lock Nut (15) 68 N.m (50 ft. lbs.) Hex Lock Nut (32) 30 N.m (22 ft. lbs.) Pinion Preload 1.8 N.m (16 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8336 Pinion Locknut 35 N.m (26 ft. lbs.) Power Steering Gear Hose Fitting Nut 27 N.m (20 ft. lbs.) Power Steering Gear Cylinder Line Fitting 27 N.m (20 ft. lbs.) Valve End Fittings 16.9 N.m (12.6 ft. lbs.) Cylinder End Fittings 27 N.m (20 ft. lbs.) Adjuster Plug Locknut 70 N.m (50 ft. lbs.) Rack and Pinion Cylinder Line: Fittings at Valve End 27 N.m (20 ft. lbs.) Fitting at Cylinder End 28 N.m (21 ft. lbs.) Rack and Pinion Mounting Bolts 120 N.m (89 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8337 Steering Gear: Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8338 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8339 Steering Gear: Service Precautions NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 8340 Steering Gear: Description and Operation The power rack and pinion steering system has a rotary control valve which directs hydraulic fluid coming from the hydraulic pump to one side or the other side of the rack piston. The integral rack piston is attached to the rack. The rack piston converts hydraulic pressure to a linear force which moves the rack left or right. The force is then transmitted through the inner and outer tie rods to the struts which turn the wheels. If hydraulic assist is not available, manual control will be maintained, however, more steering effort will be required. The movement of the steering wheel is transferred to the pinion. The movement of the pinion is then transferred through the pinion teeth, which mesh with teeth on the rack, causing the rack to move. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Steering Gear: Symptom Related Diagnostic Procedures Diagnostic Information & Procedures GENERAL PROCEDURE Inspect ^ Overfilled reservoir. ^ Fluid aeration and overflow. ^ Hose connections. ^ Verify exact point of leakage. Example: The point from which the fluid is dripping is not necessarily the point where the system is leaking. Fluid overflowing from the reservoir may appear to be dripping from the bottom of the housing. Important: ^ When service is required: a. Clean leakage area upon disassembly. b. Replace leaking seal. c. Check component sealing surfaces for damage. d. Reset bolt tightening specification, where required. Important: ^ Some complaints about the power steering system may be reported as: a. Fluid leakage on garage floor. b. Fluid leaks visible on steering gear or pump. c. Growling noise, especially when parking or when engine is cold. d. Loss of power steering when parking. e. Heavy steering effort. When troubleshooting these kinds of complaints, check for an external leak in the power steering system. For further diagnosis of leaks, refer to EXTERNAL LEAKAGE CHECK. EXTERNAL LEAKAGE CHECK Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8343 Power Steering Gear Leak Diagnosis Power Steering Pump Leak Diagnosis The purpose of this procedure is to pinpoint the location of the leak. In some cases, the leak can easily be located. But, seepage-type leaks may be more difficult to isolate. To locate seepage leaks, use the following method. 1. With the engine off, wipe dry the complete power steering system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8344 2. Check the fluid level in the pump's reservoir. Adjust fluid level as necessary. 3. Start the engine, then turn the steering wheel from stop to stop several times. Do not hold it at a stop for any length of time, as this can damage the power steering pump. It is easier if someone else operates the steering wheel while you search for the seepage. 4. Find the exact area of the leak and repair leak. Diagnosis By Symptom HISSING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound when the steering wheel is turned and the vehicle is not moving. This noise will be most evident when turning the wheel while the brakes are applied. There is no relationship between this noise and steering performance. Do not replace the valve and pinion unless the "hissing" noise is extremely objectionable. A replacement valve and pinion will also have a slight noise, and is not always a cure for the condition. Check that the intermediate shaft joints are not loose. RATTLE OR CHUCKING NOISE Inspect ^ Power steering hose or line grounding out. ^ Loose steering gear mounting. ^ Rack bearing preload loose. ^ Intermediate shaft boot mispositioned. ^ For more diagnostic information on these symptoms, Refer to SUSPENSION GENERAL DIAGNOSIS. POOR RETURN OF STEERING WHEEL TO CENTER Inspect ^ Intermediate shaft binding or loose. ^ Tight or frozen steering shaft bearings. ^ Rack bearing preload. ^ Sticky or plugged valve and pinion. ^ Intermediate shaft boot mispositioned. ^ For more diagnostic information on these symptoms, Refer to SUSPENSION GENERAL DIAGNOSIS. MOMENTARY INCREASE IN EFFORT WHEN TURNING WHEEL FAST TO RIGHT OR LEFT (ESPECIALLY WHEN COLD) Inspect ^ High internal leakage in gear or pump. ^ Hose pinched or restricted. ^ Sticking flow control valve. ^ Low fluid level in pump reservoir. STEERING WHEEL SURGES OR JERKS WHEN TURNING WITH ENGINE RUNNING (ESPECIALLY DURING PARKING, OR COLD) Inspect ^ Belt slipping. ^ Insufficient pump pressure. EXCESSIVE WHEEL KICKBACK OR LOOSE STEERING Inspect ^ Air in system. ^ Steering gear attachments loose. ^ Intermediate shaft loose. ^ Rack bearing preload. ^ For more diagnostic information on these symptoms, Refer to SUSPENSION GENERAL DIAGNOSIS. HARD STEERING OR LACK OF ASSIST (ESPECIALLY DURING PARKING) Inspect ^ Loose or worn intermediate shaft. ^ Loose belt. ^ Insufficient pump pressure. ^ High internal leakage in gear or pump. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8345 Steering Gear: Component Tests and General Diagnostics Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the valve and pinion and on the drive shaft of the pump. When there is a leak in one of these areas, always replace the seal(s), after inspecting and thoroughly cleaning the sealing surfaces. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by first smoothing with crocus cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service Steering Gear: Service and Repair On-Vehicle Service Gear Inlet Hose Power Steering Restrictor Valve And Hose Routing Power Steering Line And Hose Routing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8348 Power Steering Line And Hose Routing Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8349 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. Tighten ^ Gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Refer to BLEEDING THE POWER STEERING SYSTEM. Gear Outlet Hose Power Steering Line And Hose Routing REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten ^ Outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten ^ Hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill with fluid and bleed air from power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8350 Inspect ^ For leaks. Manual Transmission REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 3. Remove the power steering hoses from the power steering gear. Refer to the following procedures: - Power Steering Pressure Hose Replacement - Power Steering Return Hose Replacement 4. Remove the tie rods from the steering knuckle. Refer to Tie Rod End Replacement - Outer On Vehicle. 5. Remove the brake pipes from the retainers on the front suspension support. 6. Remove the lower pinch bolt from the intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Column - Standard. 7. Support the front suspension support (2) with a suitable jack stand. 8. Remove the front suspension cross member mounting bolts. Refer to Front Suspension Cross member Replacement in Suspension. 9. Lower the front suspension support (2) in order to remove the power steering gear (1). 10. Remove the power steering gear mounting bolts (3). 11. Remove the power steering gear from the vehicle. INSTALLATION PROCEDURE 1. Install the power steering gear (1) to the vehicle. 2. Install the power steering gear mounting bolts (3). Hand tighten the bolts. 3. Raise the front suspension support (2) into position on the vehicle. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the front suspension support mounting bolts. 4.1. Tighten the left rear outboard bolt to 110 Nm (71 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8351 4.2. Tighten the right rear outboard bolt to 110 Nm (71 ft. lbs.). 4.3. Tighten the rear inboard bolts to 110 Nm (71 ft. lbs.). 4.4. Tighten the power steering gear mounting bolts to 0120 Nm (89 ft. lbs.). 5. Install the lower pinch bolt to the intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Column Standard. 6. Install the brake pipes to the retainers on the front suspension support. 7. Install the tie rod ends to the steering knuckle. Refer to Tie Rod End Replacement - Outer On Vehicle. 8. Install the power steering hoses to the power steering gear. Refer to the following procedures: - Power Steering Pressure Hose Replacement - Power Steering Return Hose Replacement 9. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. 10. Bleed the power steering system. Refer to Bleeding Power Steering System in Service and Repair of Steering. 11. Align the front wheels. Refer to Measuring Wheel Alignment (Front) in Alignment. Automatic Transmission REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the front suspension cross member. Refer to Front Suspension Crossmember Replacement in Suspension 3. Remove the power steering gear mounting bolts (3). 4. Remove the power steering gear (1) from the front suspension support assembly (2). INSTALLATION PROCEDURE 1. Install the power steering gear (1) to the front suspension cross member (2). NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the power steering gear mounting bolts (3) Tighten the bolts to 120 Nm (89 ft. lbs.). 3. Install the front suspension support assembly. Refer to Front Suspension Cross member Replacement in Suspension 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8352 Steering Gear: Service and Repair Unit Repair Outer Tie Rod Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8353 ^ Tool Required: J 24319-01 Universal Steering Linkage Puller - Or Equivalent REMOVE OR DISCONNECT 1. Hex torque prevailing nut (1) from outer tie rod assembly (5). 2. Loosen jam nut (7). 3. Outer tie rod (5) from steering knuckle with J 24319-01. 4. Outer tie rod (5) from inner tie rod (12). INSTALL OR CONNECT 1. Outer tie rod assembly (5) to inner tie rod (12). Do not tighten jam nut (7). 2. Outer tie rod (5) to steering knuckle, hex torque prevailing nut (1) to outer tie rod stud. ^ Tighten: Hex torque prevailing nut (1) to 10 Nm (7 ft. lbs.). - Tighten nut an additional 210° of rotation. ^ Adjust toe by turning inner tie rod (12). Important: Be sure rack and pinion boot (10) is not twisted or puckered during toe adjustment. ^ Tighten jam nut (7) against outer tie rod (5) to 68 Nm (50 ft. lbs.). Rack Bearing Preload (on Vehicle Adjustment) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8354 1. Make adjustment with front wheels raised and steering wheel centered. Be sure to check returnability of the steering wheel to center after adjustment. 2. Loosen adjuster plug lock nut (15) and turn adjuster plug clockwise until it bottoms in gear assembly (30), then back off 50° to 70° (approximately one flat). 3. Lock nut (15) to adjuster plug. ^ Tighten lock nut (15) to 68 Nm (50 ft. lbs.) while holding adjuster plug stationary. Inner Tie Rod Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8355 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8356 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8357 REMOVE OR DISCONNECT 1. Rack and pinion assembly from vehicle. 2. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "REMOVE OR DISCONNECT. 3. Shock dampener (13) from inner tie rod assembly (12) and slide back on rack. NOTICE: Rack must be held during removal of inner tie rod (12) to prevent rack damage. 4. Inner tie rod assembly (12) from rack assembly as follows. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Rotate inner tie rod housing counterclockwise until inner tie rod (12) separates from rack. INSTALL OR CONNECT Important: Rack must be held during inner tie rod (12) installation to prevent internal gear damage. 1. Shock dampener (13) onto rack. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8358 2. Inner tie rod (12) on rack. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Tighten inner tie rod (12) to 100 Nm (74 ft. lbs.). Important: Make sure tie rod rocks freely in housing before staking inner tie rod assembly (12) to rack. 3. Support rack and housing of inner tie rod assembly (12) and stake both sides of inner tie rod housing to flats on rack. ^ Check both stakes by inserting a 0.25 mm (.010 in.) feeler gauge between rack and tie rod housing. Feeler must not pass between rack and housing stake. 4. Slide shock dampener (13) over inner tie rod housing until it engages. 5. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "INSTALL OR CONNECT." 6. Rack and pinion assembly to vehicle. Cylinder Line Assembly and O-Ring Seals Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8359 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8360 ^ Tools Required: 12mm Flare Nut Wrench - 16mm Flare Nut Wrench REMOVE OR DISCONNECT 1. Loosen cylinder line fittings (25) or (26) on cylinder end of gear assembly (30). 2. Loosen fittings on cylinder line assemblies (25) or (26) at valve end of gear assembly (30). 3. Cylinder line assemblies (25) or (26) from rack and pinion gear assembly (30). 4. O-ring seals (23) from valve end of lines (25) or (26) and discard. INSTALL OR CONNECT Inspect lines for: ^ Cracks. ^ Dents. ^ Damage to threads. ^ Replace as needed. 1. New O-ring seals (23) to valve end of lines (25) or (26). 2. Cylinder line assemblies (25) or (26) to gear assembly (30). NOTICE: Carefully align threads on all fittings and finger tighten to avoid stripping and cross-threading. ^ Tighten: Valve end fittings to 16.9 Nm (12.6 ft. lbs.). - Cylinder end fittings to 27 Nm (20 ft. lbs.). Rack & Pinion Boot and Breather Tube Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8361 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8362 ^ Tool Required: J 22610 Service Boot Clamp Installer - Or Equivalent REMOVE OR DISCONNECT 1. Do all steps of OUTER TIE ROD under "REMOVE OR DISCONNECT." 2. Hex jam nut (7) from inner tie rod assembly (12). 3. Tie rod end clamp (8). 4. Boot clamp (11) with side cutters and discard. Important: Mark location of breather tube (35) on gear assembly (30) before removing tube (35) or rack and pinion boot (10). 5. Rack and pinion boot (10) and breather tube (35). INSTALL OR CONNECT 1. New boot clamp (11) onto rack and pinion boot (10). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8363 2. Apply grease to inner tie rod (12) and gear assembly (30) prior to boot installation. ^ Boot (10) onto inner tie rod assembly (12). 3. Breather tube (35) aligned with mark made during removal, molded nipple of boot (10) to tube (35). 4. Boot (10) onto gear assembly (30) until seated in gear assembly groove. Important: Boot (10) must not be twisted, puckered or out of shape in any way. If the boot is not shaped properly, adjust by hand before installing boot clamp (11). 5. Boot clamp (11) on boot (10) with tool J 22610 and crimp as shown. 6. Tie rod end clamp (8) with pliers on boot (10). 7. Hex jam nut (7) to inner tie rod assembly (12). 8. Do all steps of OUTER TIE ROD under "INSTALL OR CONNECT." Pinion Seal, Dust Seal and Bearing/Annulus Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8364 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8365 ^ Tools Required: J 29810 Stub Shaft Seal Protector, Or Equivalent - 14 mm Crowfoot Wrench REMOVE OR DISCONNECT 1. Rack and pinion steering assembly from vehicle). 2. Adjuster plug lock nut (15) from adjuster plug. 3. Adjuster plug from gear assembly (30). 4. Adjuster spring and rack bearing. 5. Retaining ring (17) from valve bore of gear assembly (30). 6. Dust cover (33) from bottom of gear assembly (30). NOTICE: Stub shaft must be held to prevent damage to the pinion teeth. 7. Hex lock nut (32) from lower end of pinion and valve assembly, while holding stub shaft with 14 mm Crowfoot Wrench. NOTICE: DO NOT hammer or pound on pinion and valve assembly. This will cause damage or loosen the drive pin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8366 Important: When performing the following procedure, do not remove pinion and valve assembly from gear assembly. Press pinion and valve assembly only far enough to allow removal of bearing/annulus and seal. Pinion and valve assembly removal is not required. 8. Use an arbor press. Press on threaded end of pinion until it is possible to remove stub shaft, spool shaft seal (20), and stub shaft bearing/annulus assembly (21). INSTALL OR CONNECT NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur. 1. Hex lock nut (32) onto pinion, while holding the valve stub shaft. ^ Tighten hex lock nut (32) to 30 Nm (22 ft. lbs.). 2. Dust cover (33) to gear assembly (30). 3. Stub shaft bearing annulus assembly (21) onto valve stub shaft. 4. Seal protector J 29810 onto valve stub shaft. 5. Apply a small quantity of grease on seal (20). ^ Spool shaft seal (20) over protector and into gear assembly (30). 6. Retaining ring (17) into groove in gear assembly (30). 7. Lubricate stub shaft and dust seal area with grease. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > On-Vehicle Service > Page 8367 8. Coat rack bearing, adjuster spring and adjuster plug with lithium base grease and install in gear assembly (30). ^ With rack centered in the gear assembly (30), turn adjuster plug clockwise until it bottoms in the gear assembly, then back off 50° to 70° (approx. one flat). Check rotational torque on pinion. Maximum pinion preload torque is 1.8 Nm (16 inch lbs.). 9. Adjuster plug lock nut (15) to adjuster plug. Tighten firmly against gear assembly while holding adjuster plug stationary. ^ Tighten lock nut (15) to 68 Nm (50 ft. lbs.) while holding adjuster plug stationary. 10. Rack and pinion assembly into vehicle. Important: Flush power steering system (hoses, reservoir and cooler lines) with power steering fluid - GM Part #1050017 (or equivalent meeting GM Specification #9985010), refer to "Flushing And Bleeding Procedures." Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 8368 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel Controls <--> [Steering Mounted Controls Transmitter] > Component Information > Service and Repair Steering Wheel Controls: Service and Repair Steering Wheel Control Switches Replacement REMOVAL PROCEDURE 1. Remove the steering wheel module. 2. Remove the horn plunger. 3. Remove the steering wheel redundant control switch mounting screws. 4. Disconnect the steering wheel redundant control switch electrical connector. 5. Remove the steering wheel redundant control switch from the steering wheel. INSTALLATION PROCEDURE 1. Install the steering wheel redundant control switch to the steering wheel. 2. Connect the steering wheel redundant control switch electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel Controls <--> [Steering Mounted Controls Transmitter] > Component Information > Service and Repair > Page 8372 NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the steering wheel redundant control switch mounting screws. Tighten Tighten the steering wheel redundant control switch mounting screws to 2 N-m (20 lb in). 4. Install the horn plunger. 5. Install the steering wheel module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: Customer Interest Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8381 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8382 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8383 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: All Technical Service Bulletins Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8389 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8390 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8391 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Nut to Shaft ................................................................................................................ .................................................... 41 N.m (30 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Steering Wheel Controls System Steering Wheel: Description and Operation Steering Wheel Controls System The steering wheel controls consist of the following components: ^ The steering wheel radio control switches ^ The SIR coil assembly ^ The radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Steering Wheel Controls System > Page 8397 Steering Wheel: Description and Operation Steering Wheel Radio Control Switches The steering wheel control switches control the following components: ^ The radio power ^ The volume ^ The station frequency These switches are a ladder network consisting of these components: ^ The switches ^ A series of resistors The ladder network is arranged so that each switch has a different resistance. The different resistances allow a different voltage output to the radio for each switch pressed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation > Steering Wheel Controls System > Page 8398 Steering Wheel: Description and Operation SIR Coil Assembly The SIR coil assembly contains 4 wires. The wires are used by the steering wheel controls. The assembly allows voltages to be sent from the steering wheel switches to the radio while the steering wheel is being turned. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service Steering Wheel: Service and Repair On-Vehicle Service Precautions The procedures must be followed in the order listed to temporarily disable the Supplemental Inflatable Restraint (SIR) System and prevent false Diagnostic Trouble Codes from setting. Failure to follow procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. The DERM can maintain sufficient voltage to cause a deployment for 10 minutes after the ignition switch is turned "OFF" or the battery is disconnected. Many of the service procedures require disconnection of the SIR fuse and inflator module circuits from the deployment loop to avoid an accidental deployment. Disabling SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. -Turn the ignition switch to "LOCK". 1. AIR BAG fuse #1. 2. Left sound insulator. 3. Connector position assurance (CPA) and yellow two-way SIR harness connector at base of steering column. Steering Wheel ^ Tool Required: - J 1859-A Steering Wheel Puller - Or Equivalent REMOVE OR DISCONNECT 1. Disable the Supplemental Inflatable Restraint (SIR) system. 2. Inflator module and horn connection. 3. Nut. 4. Steering wheel using J 1859-A. INSTALL OR CONNECT 1. Align mark on steering wheel with mark on shaft, then install steering wheel. 2. Nut. ^ Tighten steering wheel nut to 41 Nm (30 ft. lbs.). 3. Horn connection and Inflator module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8401 4. Enable the SIR system. Enabling the SIR System INSTALL OR CONNECT 1. Turn ignition switch to "OFF". 2. Route wire around post on back of module and under tab. 3. Yellow two-way Supplemental Inflatable Restraint (SIR) connector and connector position assurance (CPA) at base of steering column. 4. Left sound insulator. 5. AIR BAG fuse #1. 6. Turn ignition to "RUN" and make sure the "INFLATABLE RESTRAINT" indicator lamp flashes 7 to 9 times and then goes out. Handling Precautions - SIR LIVE (UNDEPLOYED) INFLATOR MODULE Special care is necessary when handling and storing a live (undeployed) Inflator Module. The rapid gas generation produced during deployment of the air bag could cause the Inflator Module, or an object in front of the Inflator Module, to be thrown through the air in the unlikely event of an accidental deployment. CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. Never carry the inflator module by the wires or connector on the underside of the module. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. When placing a live inflator module on bench or other surface, always face the bag and trim cover up, away from the surface. Never rest a steering column assembly on the steering wheel with the inflator module face down and column vertical. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. DEPLOYED INFLATOR MODULES After an Inflator Module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of corn starch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye is produced as a by-product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. As with many service procedures, you should wear gloves and safety glasses. INFLATOR MODULE SHIPPING PROCEDURES FOR LIVE (UNDEPLOYED) INFLATOR MODULES Service personnel should refer to the latest Service Bulletins for proper Supplemental Inflatable Restraint (SIR) inflator module shipping procedures. INFLATOR MODULE SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. This information covers proper procedures for disposing of a live inflator module. Before a live inflator module can be disposed of, it must be deployed. Live inflator modules must not be disposes of through normal refuse channels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8402 CAUTION: Failure to follow proper Supplemental Inflatable Restraint (SIR) inflator module disposal procedures can result in air bag deployment which may cause personal injury. Undeployed inflator modules must not be disposed of through normal refuel channels. The undeployed inflator module contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal. Disposal in any manner inconsistent with proper procedures may be a violation of federal, state, and/or local laws. If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), DO NOT DEPLOY the inflator module and SO NOT ALTER the SIR system in any manner. Refer to the applicable service bulletin on SIR shipping procedures for details on handling SIR systems involved with GM-1241. If a vehicle is the subject of a campaign affecting inflator modules, DO NOT DEPLOY the inflator module. Follow instruction in the Campaign Service Bulletin for proper disposition of the inflator module. If an inflator module is replaced under warranty, DO NOT DEPLOY the air bag. The inflator module may need to be returned, undeployed, to Inland Fisher Guide. Refer to procedures shown in the appropriate service bulletin regarding SIR shipping procedures. In situations which require deployment of alive (undeployed) driver inflator module, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment Inside Vehicle." WIRING REPAIR SUPPLEMENTAL INFLATABLE RESTRAINT If the wiring pigtail (wires attached directly to the component, not by a connector) on either the Inflator Module or the SIR Coil Assembly is damaged, the entire component must be replaced. Absolutely no wire, connector, or terminal repairs are to be attempted on either the Inflator Module or the SIR Coil Assembly. Inflator Module - Supplemental Inflatable Restraint (SIR) REMOVE OR DISCONNECT 1. Disable the Supplemental Inflatable Restraint (SIR) system. 2. Two screws from the back of the steering wheel using a Hex Head driver (or equivalent). 3. Connector position assurance (CPA) and electrical connection from rear of inflator module. 4. Inflator module. INSTALL OR CONNECT 1. CPA to rear of inflator module. 2. Inflator module to steering wheel and four screws through back of steering wheel. ^ Tighten screws to 10 Nm (89 inch lbs.). 3. Enable the SIR system. Coil Assembly- Supplemental Inflatable Restraint (SIR) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8403 REMOVE OR DISCONNECT Important: Disable the Supplemental Inflatable Restraint (SIR) system. 1. Steering wheel assembly. 2. Coil assembly retaining clip. 3. Coil assembly off shaft end letting coil hang freely. 4. Wave washer. 5. Spacer shaft lock (standard column only). 6. Shaft lock retaining ring using J 23563-C to compress lock. 7. Pry off retaining ring. 8. Shaft lock. 9. Turn signal canceling cam assembly. 10. Upper bearing spring. 11. Turn signal to right turn position (up). 12. Multifunction lever. 13. Hazard knob assembly. 14. Screw and signal switch arm. ^ Let switch arm hang freely (tilt option equipped with cruise only). 15. Screws, turn signal switch. ^ Let turn signal switch hang freely. 16. Remove coil assembly connector shroud. 17. Steering column support bracket bolts. 18. Upper steering column bolts. 19. Wiring protector. 20. Connect a length of mechanic's wire to coil assembly terminal connector to aid in reassembly. 21. Gently pull wire harness through steering column housing shroud, steering column housing and lock assembly cover. 22. Remove mechanic's wire. INSTALL OR CONNECT NOTICE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8404 1. Connect mechanic's wire to centering coil assembly connector. 2. Gently pull connector through steering column housing shroud, steering column housing and lock assembly. 3. Remove mechanic's wire. 4. Install wiring protector. 5. Install connector shroud. 6. Connector centering coil assembly terminal connector. 7. Steering column lower support bracket to steering column. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 8. Steering column upper support bolts. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 9. Turn signal switch assembly. ^ Tighten bolts to 3.4 Nm (30 inch lbs.). 10. Signal switch arm (tilt steering column only). ^ Tighten bolts to 2.3 Nm (20 inch lbs.). 11. Hazard knob assembly. 12. Multifunction lever. 13. Turn signal canceling cam assembly. ^ Lubricate with grease, synthetic (service kit). 14. Shaft lock. ^ Inspect shaft lock retaining ring for damage or deformation. Replace with new retaining ring. 15. Shaft lock retaining ring. Line up to block tooth on shaft using J 23653-C to compress shaft lock. ^ Shaft lock retaining ring must be firmly seated in groove on shaft. 16. Spacer shaft lock (standard column only). 17. Ensure coil assembly is centered. Important: Assemble pre-centered coil assembly to steering column. Remove centering tab and dispose. Important: Coil assembly will become un-centered if: a. Steering column is separated form steering gear and is allowed to rotate. b. Centering spring is pushed down, letting hub rotate while coil is removed from steering column. In the event this occurs, refer to "Centering Coil Assembly." 18. Coil assembly using horn tower on canceling cam assembly inner ring and projections on outer ring for alignment. 19. Coil assembly retaining ring. ^ Ring must be firmly in groove on shaft. Important: Gently pull lower coil assembly wire to remove any wire kinks that may be inside column assembly. It is absolutely critical that you make sure there are no kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Then turning of the steering wheel may cut or damage wire. 20. Steering wheel assembly. 21. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8405 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8406 Steering Wheel: Service and Repair Supplemental Inflatable Restraint (SIR) The supplemental Inflatable Restraint (SIR) system helps supplement the protection offered by the driver's seat belt by deploying an air bag from the center of the steering wheel during certain frontal crashes. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30° off the centerline of the vehicle. The steering column is collapsible and should be inspected after an accident whether or not deployment has occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > On-Vehicle Service > Page 8407 Steering Wheel: Service and Repair Lubrication Apply a thin coat of lithium grease to all friction parts when assembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Page 8408 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod Tie Rod: Service and Repair Outer Tie Rod Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod > Page 8413 ^ Tool Required: J 24319-01 Universal Steering Linkage Puller - Or Equivalent REMOVE OR DISCONNECT 1. Hex torque prevailing nut (1) from outer tie rod assembly (5). 2. Loosen jam nut (7). 3. Outer tie rod (5) from steering knuckle with J 24319-01. 4. Outer tie rod (5) from inner tie rod (12). INSTALL OR CONNECT 1. Outer tie rod assembly (5) to inner tie rod (12). Do not tighten jam nut (7). 2. Outer tie rod (5) to steering knuckle, hex torque prevailing nut (1) to outer tie rod stud. ^ Tighten: Hex torque prevailing nut (1) to 10 Nm (7 ft. lbs.). - Tighten nut an additional 210° of rotation. ^ Adjust toe by turning inner tie rod (12). Important: Be sure rack and pinion boot (10) is not twisted or puckered during toe adjustment. ^ Tighten jam nut (7) against outer tie rod (5) to 68 Nm (50 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod > Page 8414 Tie Rod: Service and Repair Inner Tie Rod Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod > Page 8415 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod > Page 8416 REMOVE OR DISCONNECT 1. Rack and pinion assembly from vehicle. 2. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "REMOVE OR DISCONNECT. 3. Shock dampener (13) from inner tie rod assembly (12) and slide back on rack. NOTICE: Rack must be held during removal of inner tie rod (12) to prevent rack damage. 4. Inner tie rod assembly (12) from rack assembly as follows. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Rotate inner tie rod housing counterclockwise until inner tie rod (12) separates from rack. INSTALL OR CONNECT Important: Rack must be held during inner tie rod (12) installation to prevent internal gear damage. 1. Shock dampener (13) onto rack. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Outer Tie Rod > Page 8417 2. Inner tie rod (12) on rack. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Tighten inner tie rod (12) to 100 Nm (74 ft. lbs.). Important: Make sure tie rod rocks freely in housing before staking inner tie rod assembly (12) to rack. 3. Support rack and housing of inner tie rod assembly (12) and stake both sides of inner tie rod housing to flats on rack. ^ Check both stakes by inserting a 0.25 mm (.010 in.) feeler gauge between rack and tie rod housing. Feeler must not pass between rack and housing stake. 4. Slide shock dampener (13) over inner tie rod housing until it engages. 5. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "INSTALL OR CONNECT." 6. Rack and pinion assembly to vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Fastener Tightening Specifications Ball Joint: Specifications Fastener Tightening Specifications Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Maximum): First ...................................................................................................................................................... ................................................ 65 N.m (50 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Minimum): First ...................................................................................................................................................... ................................................ 55 N.m (41 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Fastener Tightening Specifications > Page 8423 Ball Joint: Specifications Wear Limit 1. Replace the ball joint if any looseness is detected in the joint. 2. Replace the bail joint if the ball joint seal is cut. 3. Inspect the ball joints. 3.1. Raise the front of the vehicle which allows the front suspension to hang free. 3.2. Grasp the tire at the top and the bottom. 3.3. Move the top of the tire with an in and out motion. 3.4. Observe ball joint for any horizontal movement of the steering knuckle, relative to the front lower amp. Replace the ball joint if movement is present. 4. Replace the ball joint if the ball stud is disconnected from the steering knuckle and looseness is detected. 5. Replace the bail joint if the ball stud can be twisted in the socket using finger pressure. 6. Check the ball stud tightness in the steering knuckle boss. 6.1. Shake the wheel while feeling for movement of the stud end or castellated nut at the knuckle boss. 6.2. Check the castellated nut fastener tightening specifications is an alternative method of inspecting for wear. A loose nut can indicate a bent stud or an opened-up hole in the knuckle boss. 7. Replace worn or damaged ball joints and knuckles. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8424 Ball Joint: Service and Repair REMOVAL PROCEDURE ^ Tools Required: J 38892 Ball Joint Separator 1. Raise and suitably support the vehicle. 2. If a suspension contact hoist is used: ^ Place the jack stands under the crossmember. ^ Lower the vehicle slightly until the weight of the vehicle resets on the crossmember. Do not rest the vehicle on the control arms. NOTICE: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of the internal components and possible joint failure. Drive axle joint protectors should be used any time service is performed on or near drive axles. Failure to observe this can result in interior joint or boot damage, and possible joint failure. 3. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL in TIRES AND WHEELS. 4. Remove the cotter pin (1) from the ball joint (3). 5. Remove the nut (4) from ball joint (3). NOTICE: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal. 6. Use the J 38892 in order to separate the ball joint from the steering knuckle. Important: Do not damage the drive axle boot when drilling out the ball joint rivets. 7. Drill out three rivets retaining the ball joint (4) to the lower control arm (2). Use a 3 mm (1/8 in) drill bit in order to make a pilot hole through the rivets. Finish drilling the rivets with a 13 mm (1/2 in) drill bit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8425 8. Remove the nut (4) attaching the link (7-11) to the stabilizer shaft (3). 9. Remove the ball joint (4) from the steering knuckle and control arm (2). INSTALLATION PROCEDURE 1. Install the ball joint (4) into the control arm, (2). 2. Install three ball joint bolts (3) and nuts (1). Follow the instructions from the ball joint kit. Tighten the bail joint bolts (3) according to the specifications in the instructions. 3. Install the ball joint stud (3) through the steering knuckle (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8426 clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the ball joint nut (4). Tighten Tighten the ball joint nut to 55 Nm (41 ft. lbs.) minimum - 65 Nm (50 ft. lbs.) maximum. Do not loosen the nut at any time during installation. 5. install the cotter pin (1). 6. Install the nut attaching the stabilizer link to the stabilizer shaft. Tighten Tighten the nut to 17 Nm (13 ft. lbs.). 7. Install the tire and wheel assemblies. Refer to WHEEL INSTALLATION in TIRES AND WHEELS. 8. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension REMOVAL PROCEDURE ^ Tools Required: J 29792 Lower Control Arm Front Bushing Set - J 41211 Lower Control Arm Vertical Bushings 1. Remove the lower control arm. Refer to LOWER CONTROL ARM REPLACEMENT. 2. Install the bushing removal tools (1, 3, 5). 3. Coat threads of J 29792 with an extreme pressure lubricant. 4. Remove the lower control arm bushings (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 8432 5. Remove the lower control arm vertical bushing (3). INSTALLATION PROCEDURE 1. Install the bushing installation tools (1, 3, 5). 2. Install the front control arm bushing (2). 3. Install the rear control arm vertical bushing (2). 4. Lubricate the outer casing of the new bushing (2). 5. Install the lower control arm bushings (2). 6. Install the lower control arm (4). Refer to LOWER CONTROL ARM REPLACEMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 8433 Control Arm Bushing: Service and Repair Rear Suspension REMOVAL PROCEDURE ^ Tools Required: J 21474-18 3/8 in Nut. - J 21474-19 3/8 in Bolt. - J 29376-A Rear Control Arm Bushing Service Set. 1. Raise and support the vehicle. 2. Support the vehicle with suitable jackstand under the axle. 3. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL. 4. If removing the: right bushings, disconnect the brake lines from the body. If removing the left bushings, disconnect the brake line bracket from the body and the parking brake cable from the hook guide on the body. NOTICE: Do not suspend rear axle by brake hoses. Damage to hoses could result. 5. Remove the nut, bolt, and washer from the control am1 and underbody attachment. Rotate the control arm downward. (Remove and install one control arm bushing at a time.) 6. Remove the bushing (1) using the following procedure: 6.1. Install the J 29376-1 into the slot in the control arm. 6.2. Position the J 29376-1 over the control arm end/bushing. 6.3. Install the J hooks through the J 29376-1 and J 29376-1 tighten the attaching nuts until the tool is securely in place. 6.4. Install the J 21474-19 bolt through the plate J 29376-7 and install into the J 29376-6. 6.5. Place the J 29376-7 remover into position on the bushing. 6.6. Install the nut J 21474-18 onto the J 21474-19 bolt. 6.7. Remove the bushing from the control arm by turning the bolt. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 8434 1. Install the bushing (1) as follows: 1.1. Install the J 29376-1 receiver on the control arm. 1.2. Install the J 21474-19 bolt through the J 29376-A plate and into the receiver. 1.3. Install the bushing on the bolt and position into the housing. Align the bushing installer arrow with the arrow on the receiver for proper indexing of the bushing. A high-pressure lubricant such as J 23444-A may be necessary for assembly. 1.4. Install J 21474-18 (3/8 in) nut onto the J 21474-19 (3/8 in) bolt. 1.5. Press the bushing-into the control arm by fuming the bolt. When the bushing is in the proper position, the end flange will be flush against the face of the control arm. Important: The washer and nut must be installed on the outboard side. 2. Align the control arm and the underbody attachment. 3. Loosely install the bolt, the washer, and the nut. 4. Install the left and right brake pipe brackets and the attaching screws. Tighten Tighten the screws to 11 Nm (97 inch lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 5. Install the tire and the wheel assemblies. Refer to WHEEL INSTALLATION. 6. Remove the jackstand and lower the vehicle to curb height. Tighten Tighten the control arm nuts to 80 Nm (59 ft. lbs.), plus 120° rotation using J 36660. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Suspension (Front) - Torque Specification Update Cross-Member: Technical Service Bulletins Suspension (Front) - Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 02-03-08-006 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Front Suspension Fastener Tightening Specifications Models: 1997-2002 Chevrolet Cavalier 1997-2002 Pontiac Sunfire This bulletin is being issued to revise the fastener tightening specifications in the Lower Control Arm Replacement Procedure and the Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following tightening specification has been revised: Control Arm to Crossmember Bolts (Front Bushing) - 100 N.m plus 90 degrees rotation (74 lb ft). DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Page 8439 Cross-Member: Specifications Crossmember Support Left Rear Outboard Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Right Rear Outboard Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Upper Front Bolts: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Rear Inboard Bolts: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Front Suspension Frame to Body Left Rear Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Front Suspension Frame to Body Right Rear Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension Cross-Member: Service and Repair Front Suspension REMOVAL PROCEDURE ^ Tool Required: J 38892 Ball Joint Separator 1. Raise the vehicle. 2. If a suspension hoist is to be used: ^ Place the jack stand under the uni-body frame near the crossmember. ^ Lower the vehicle slightly so the weight of the vehicle rests on the under uni-body frame. Do not rest on the control arms or crossmember. 3. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL in TIRES AND WHEELS. 4. Disconnect the right and left wiring harnesses from the crossmember. NOTICE: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal. 5. Use the J 38892 in order to remove the ball joint (3) from the knuckle (2). 6. Remove the engine strut mount from the crossmember. Refer to ENGINE. 7. Remove the crossmember extension brace (3) bolts (2 and 4) from the lower tie bar (5). ^ Remove the front exhaust pipe. Support the catalytic converter. Refer to CATALYTIC CONVERTER in EXHAUST SYSTEM. 8. Remove the power steering gear bolts. Support the power steering gear. 9. Disconnect the brake lines from the retainers on the crossmember Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8442 10. Remove the splash shield from the crossmember. 11. Remove the stabilizer bar (3) from the crossmember (5). 12. Remove the crossmember bolts (2 through 8). 13. Remove the crossmember. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8443 14. Remove the control arms (3) from the crossmember (1). INSTALLATION PROCEDURE 1. Install the control arms (3) to the crossmember (1). Snug the bolts. 2. Install the crossmember. Finger tighten all of the bolts. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Tighten the bolts in the sequence shown below: Tighten ^ Tighten the crossmember support left rear outboard bolt to 110 Nm (71 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support right rear outboard bolt to 110 Nm (71 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support upper front bolts to 90 Nm (66 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support rear inboard bolts to 110 Nm (71 ft. lbs.) plus a 90 rotation. Important: Do not loosen the nut any time during the installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8444 4. Install the nut (4) attaching the ball joint (3) to the steering knuckle (2). Tighten Tighten the nut to 55 Nm (41 ft. lbs.) minimum - 65 Nm (50 ft. lbs.) maximum. 5. install the cotter pin (1). 6. Install the left power steering gear bolts. Refer to POWER STEERING GEAR AND PUMP in STEERING for fastener tightening specifications. 7. Install the right power steering gear bolts. Refer to POWER STEERING GEAR AND PUMP in STEERING for fastener tightening specifications. 8. Install the front exhaust pipe. Refer to ENGINE EXHAUST in EXHAUST for tightening specifications. 9. Install the crossmember support braces. Tighten Tighten the core support bolts to the crossmember braces to 72 Nm (53 ft. lbs.). 10. Install the engine strut mount to the crossmember. Refer to ENGINE for tightening specifications. 11. Install the stabilizer bar (3) to the crossmember (5). Tighten Tighten the stabilizer shaft to support the assembly bolt to 66 Nm (49 ft. lbs.). 12. Install the splash shield to the crossmember (5). 13. Connect the brake lines to the retainers to the crossmember. 14. Install the right and left wiring harnesses to the crossmember. 15. Slightly raise the vehicle. 16. Remove the jack stand from under the crossmember. 17. Install the tire and wheel assemblies. Refer to WHEEL INSTALLATION in TIRES AND WHEELS. 18. Tighten the control arm attaching bolts, with the vehicle at curb height. Tighten ^ Tighten the control arm to crossmember bolts (front bushing) to 100 Nm (74 ft. lbs.) plus 180° rotation. ^ Tighten the control arm crossmember bolts, (vertical bushing) to 170 Nm (125 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8445 19. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8446 Cross-Member: Service and Repair Rear Suspension REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Support the rear axle assembly (1) with suitable jackstands. 3. Remove the both rear tires and the wheel assembly. Refer to WHEEL REMOVAL. 4. Disconnect the brake pipe at the brake pipe brackets on the axle assembly. Refer to PIPE REPLACEMENT in HYDRAULIC BRAKES. This will ensure that the axle assembly is not suspended by the brake pipes and the hoses. Plug the brake pipe openings to prevent loss of brake fluid from master cylinder. 5. Remove the lower shock absorber mount bolt (4). 6. Lower the rear axle. 7. Disconnect the parking brake at the equalizer unit. Refer to PARKING BRAKE. 8. Disconnect the rear ABS wiring connector. 9. Remove the right brake lines and the left brake lines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8447 10. Remove the axle assembly attaching bolts (1) with an assistant. 11. Remove the axle assembly (1). INSTALLATION PROCEDURE 1. Position the rear axle assembly (1) into place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 8448 2. Loosely install the attaching bolts (1). Tighten Tighten the axle attaching bolts to 80 Nm (59 ft. lbs.), plus 120° at curb height. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the right brake lines and the left brake lines. 4. Connect the ABS wiring connector. 5. Connect the parking brake cable at the right rear wheel cable connector and the cable equalizer. 6. Install both springs (2) and insulators (1) while carefully raising the axle assembly and positioning the axle assembly in order to install the lower shock absorber mount stud and nut (5). 7. Lower the shock absorber mount nuts (5). Tighten Tighten the shock absorber lower attaching nut to 47 Am (35 ft. lbs.). 8. Install the left and the right side brake line bracket mount bolts to the body. Tighten Tighten the screws to 11 Nm (97 inch lbs.). 9. Install the tire and wheel assembly. Refer to WHEEL INSTALLATION. 10. Lower the vehicle. 11. Fill and bleed the rear brake system. Refer to HYDRAULIC BRAKE SYSTEM BLEEDING. 12. Adjust the parking brake. Refer to PARK BRAKE CABLE SERVICE/ADJUSTMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Maximum): First ...................................................................................................................................................... ................................................ 65 N.m (50 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Ball Joint to Steering Knuckle Nut to Install Cotter Pin (Minimum): First ...................................................................................................................................................... ................................................ 55 N.m (41 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Caliper to Knuckle Bolts ...................................................................................................................... ................................................... 51 N.m (38 ft. lbs.) Hub and Bearing Assembly to Steering Knuckle Bolts ........................................................................................................................... 95 N.m (70 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 8452 Front Steering Knuckle: Testing and Inspection 1. Check the ball stud tightness in the steering knuckle boss. 1.1. Shake the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. 1.2. Check the castellated nut fastener tightening specifications is an alternative method of inspecting for wear. A loose nut can indicate a bent stud or an opened-up hole in the knuckle boss. 2. Replace worn or damaged ball joints and knuckles. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions Front Steering Knuckle: Service and Repair Repair Instructions REMOVAL PROCEDURE ^ Tools Required: J 38892 Ball Joint Separator - J 28733-B Front Hub Spindle Remover 1. Remove the hub and bearing assembly (1). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 2. Remove the bolts (6) attaching the steering knuckle (3) to the strut (1). 3. Remove the cotter pin (1). 4. Remove the nut (4) from the ball joint (3). 5. Use the J 38892 in order to separate the ball joint (3) from the knuckle (2). 6. Remove the knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8455 1. Install the steering knuckle (2) to the ball joint (3). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the ball joint nut (4). Tighten Tighten the ball joint nut to 55 Nm (41 ft. lbs.) (minimum) and 65 Nm (50 ft. lbs.) (maximum). 3. Install the cotter pin (1). 4. Install the steering knuckle (3) into the strut (1). 5. Install the steering knuckle to strut assembly bolts (6). Tighten Tighten the nuts (2) to 180 Nm (133 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8456 6. Install the hub and bearing assembly (1) onto the knuckle (2). 7. Install the hub and bearing assembly bolts (1). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 8. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Repair Instructions > Page 8457 Front Steering Knuckle: Service and Repair Strut and Knuckle Scribing SCRIBING PROCEDURE 1. Scribe the knuckle along the lower outboard strut radius (shown by the dotted line). Use a sharp tool. 2. Scribe the strut flange on the inboard side along the curve of the knuckle (shown by the dotted line). 3. Make a scribe mark across the strut/knuckle interface. 4. Match the marks to the components during reassembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Specifications Rear Knuckle Alignment Link: Specifications Inner Tie Rod Bolts .............................................................................................................................. ................................................... 90 N.m (65 ft. lbs.) Tie Rod End to Strut Nut: First ...................................................................................................................................................... ................................................ 20 N.m (15 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Stabilizer Shaft Bushing Clamp: To Crossmember Support Bolts ........................................................................................................................................................... 66 N.m (49 ft. lbs.) Stabilizer Shaft Link to Control Arm Nuts .............................................................................................................................................. 17 N.m (13 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Coil Over Shock Absorber: Adapter ................................................................................................................................................ ................................................ 70 N.m (52 ft. lbs.) Upper Mounting Bolt ............................................ ............................................................................................................................... 28 N.m (21 ft. lbs.) Lower Mounting Bolt ............................................................................................................................ .......................................... 170 N.m (125 ft. lbs.) Mounting Upper Bolt to Body ............................................................................................................................................................. 28 N.m (21 ft. lbs.) Mounting Nut ......................................................................................................... ............................................................................. 20 N.m (15 ft. lbs.) Upper Mount to Shock Nut ...... ............................................................................................................................................................ 20 N.m (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 8472 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 8473 Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Replacement Guidlines File In Section: Warranty Administration Bulletin No.: 72-05-12 Date: January, 1998 WARRANTY ADMINISTRATION Subject: Replacement of Shock Absorbers and Struts Labor Operations E3800, E3801, E3807, E5800, E5801, E5807, E3850, E3851, E3857, E5750, E5751, and E5757 Models: All Past, Present, and Future Passenger Cars & Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with enhanced service policies for the above listed subject labor operations. Service Management should make certain that all dealership personnel responsible for replacement of suspension components are familiar with GM Service Manual procedures. Effective with repair orders dated on or after January 15, 1998 the following must also be followed: - Shock absorber/strut assemblies are fluid filled components and will normally exhibit seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorber/strut assemblies are not to be replaced under warranty or seepage. - Defective shock absorber/strut assemblies will have a visible oil path or drip coming from the component. A visible oil path or drip coming from the shock absorber/strut assembly should be replaced as a defective component. - Only defective shock absorber/strut assemblies should be replaced. DO NOT replace pairs unless both are defective, unless otherwise instructed in the Service Manual and/or Service Bulletin. - Service Management approval is required on the repair order for replacement of struts or shocks in pairs. This approval includes noting the reason for replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 8474 Suspension Strut / Shock Absorber: Specifications Strut Assembly to Body Bolt ................................................................................................................ ................................................... 25 N.m (18 ft. lbs.) Strut Assembly to Body Nuts ............................ ...................................................................................................................................... 25 N.m (18 ft. lbs.) Strut Assembly to Steering Knuckle Nuts ............................................................................................................................................ 180 N.m (133 ft. lbs.) Strut Nut to Strut Rod ...................................................................................................... ........................................................................ 70 N.m (52 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Steering/Suspension Shock Absorber REMOVAL PROCEDURE 1. Remove the coil-over shock absorber (5) lower nut. 2. Remove the coil-over lower adapter bolt (4) and the nut. INSTALLATION PROCEDURE 1. Install the coil-over shock (5) lower adapter (3) and the bolt (4). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the shock absorber lower nut. Tighten Tighten the coil-over shock absorber nut to 70 Nm (52 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8477 Suspension Strut / Shock Absorber: Service and Repair Front Suspension Strut and Knuckle Scribing SCRIBING PROCEDURE 1. Scribe the knuckle along the lower outboard strut radius (shown by the dotted line). Use a sharp tool. 2. Scribe the strut flange on the inboard side along the curve of the knuckle (shown by the dotted line). 3. Make a scribe mark across the strut/knuckle interface. 4. Match the marks to the components during reassembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8478 Strut Replacement (Strut Removal) REMOVAL PROCEDURE ^ Tools Required: J 24319-01 Tie Rod Puller 1. Remove the nuts (1) and bolt (2) attaching the top of the strut assembly to the body (3). 2. Raise and suitably support the vehicle. 3. Place a jackstand under the front crossmember if it will be supported by a suspension lift. 4. Lower the vehicle. Ensure that the weight of the vehicle rests on the jack stand rather than the control arms. 5. Remove the tire and wheel assembly. Refer to WHEEL REMOVAL in TIRES AND WHEELS. 6. Remove the brake line bracket. 7. Scribe the strut flange. Refer to STRUT AND KNUCKLE SCRIBING. NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. Important: The steering knuckle must be supported to prevent an axle joint over-extension. 8. Remove the bolts (6) attaching the strut (1) to the steering knuckle (3). 9. Remove the strut assembly (1) from the vehicle. INSTALLATION PROCEDURE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension cold spring. Damage can cause premature failure. 1. Install the strut (1) into position. 2. Install the two nuts (1) and one bolt (2) connecting the strut assembly to the body. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8479 3. Align the steering knuckle (3) with a strut flange scribe mark and install the bolts (6) and nuts (2). Tighten Tighten the nuts to 130 Nm (133 ft. lbs.). 4. Tighten the nuts (1) attaching the top of the stout assembly to the body. Tighten Tighten to 25 Nm (18 ft. lbs.). 5. Tighten the bolt (2) attaching the top of the strut assembly to the body. Tighten Tighten to 25 Nm (18 ft. lbs.). 6. Install the brake line bracket. 7. If a suspension contact hoist is used: 7.1. Slightly raise the vehicle. 7.2. Remove the jackstand from under the crossmember. 8. Install the tire and wheel assembly. Refer to WHEEL INSTALLATION in TIRES AND WHEELS. 9. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Strut Replacement (Strut Modification) ADJUSTMENT PROCEDURE Perform stout modification on or off the vehicle. 1. Elongate the lower strut to knuckle hole (2) on the strut (1) before adjusting the camber. This allows movement of the knuckle. 2. Paint the filed area after modification. Painting protects the are from corrosion. Use a rust preventative paint. 3. Disconnect the strut (1) from the knuckle if the strut is on the vehicle. Place the strut in a vise if the strut is off the vehicle. 4. File the lower hole (2) until the outer flange slot match the inner flange slot. 5. Reconnect the strut to the knuckle. 6. Check the wheel alignment. Refer to MEASURING WHEEL ALIGNMENT (FRONT ALIGNMENT ANGLES). 7. Adjust camber if necessary. Refer to FRONT CAMBER ADJUSTMENT. Strut, Strut Component and/or Spring Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8480 REMOVAL PROCEDURE ^ Tools Required: J 3269-20 Holding Fixture - J 34013-B Strut Compressing Tool - J 34013-20 Dampener Rod Clamp - J 34013-27 Alignment Rod NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Mount the J 34013-B and thee J 3289-20. 2. Mount the strut (1) into the J 3289-20. Take notice that the J 34013-B has the strut mounting holes drilled for a specific car line. 3. Compress the strut approximately 1/2 the height after the initial contact with the cap. Do not bottom the spring (1) or dampen the rod. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8481 4. Remove the nut (2) from the strut dampener shaft. 5. Place the J 34013-27 on top of the dampen shaft. Use this rod to guide the dampen shaft straight down through the bearing cap while decompressing the spring (1). 6. Remove the components 1 through 10. INSTALLATION PROCEDURE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8482 1. Install the bearing cap if it had been previously removed from the top of the strut (8). 2. Mount the strut into the J 34013-B using the bottom locking pin only. 3. Extend dampener shaft (1) and install the J 34013-20 onto the dampener shaft. 4. Install the spring (6) over the dampener. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8483 5. Swing the assembly up for the upper locking pin (2) to be installed. 6. Install the-upper insulator (5). 7. Install the shield (10). Install the bumper (9). 8. Install the upper spring seat. Important: The flat on the lower spring seat is NOT perpendicular to the strut/knuckle opening. 9. Face the upper spring seat flat in the same direction as the centerline of the strut/knuckle assembly spindle. 10. Install the J 34013-27. 11. Turn the forcing screw (3) while the J 34013-27 centers the assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Steering/Suspension Shock Absorber > Page 8484 12. Remove the J 34013-27 and install the nut (2) when the threads on the dampen shaft are visible. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 13. Tighten the nut (2). Tighten Tighten the nut to 70 Nm (52 ft. lbs.). 14. Use a line wrench (1) while holding the dampen shaft with the socket. 15. Remove the clamp Use the J 34013-20 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT WHEEL BEARINGS AND/OR HUB REMOVAL PROCEDURE ^ Tools Required: J 28733-B Front Hub Spindle Remover 1. Remove the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in Drive Axles, Bearings and Joints. 2. Remove brake caliper bolts and support caliper. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 3. Remove the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Remove the bolts (1) from the hub and bearing assembly (3). 5. Remove the hub and bearing assembly (1) from the steering knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8490 1. Install the hub and bearing assembly (1) into the steering knuckle (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the hub and bearing bolts (1) and washers (2). Tighten Tighten the bolts to 95 Nm (70 ft. lbs.). 3. Install the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Install the brake caliper and bolts. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 5. Install the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in DRIVE AXLES, BEARINGS AND JOINTS. 6. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 8491 Wheel Bearing: Service and Repair Rear REAR HUB AND/OR BEARINGS REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the brake drum. Refer To BRAKE DRUM REPLACEMENT. 4. Remove the hub and bearing assembly (4) from the axle (2). The top rear attaching bolt (5) and nut (1) will not clear the brake shoe (3) when removing the hub and bearing assembly. Partially remove the hub and bearing assembly prior to removing this bolt. 5. Disconnect the rear ABS wheel speed sensor wire connector. INSTALLATION PROCEDURE 1. Connect the rear ABS wheel speed sensor wire connector. 2. Install the hub and bearing assembly (4). Position the top rear attaching bolt (5) in the hub and bearing assembly prior to the installation in the axle assembly (2). Tighten Tighten the hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 4. Install the tire and wheel assemblies. Refer to WHEEL REMOVAL. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Drive Axle Nut 200 Nm (144 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 8497 Axle Nut: Specifications Rear Hub and Bearing to Axle Bolts 60 Nm (44 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE Caution: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack. Caution: To help avoid personal injury, when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which you are removing components. The additional support will reduce the possibility of the vehicle falling off the hoist. When you are removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads at the same end from which you are removing the major components to prevent tip-off. If you fail to follow these precautionary measures, vehicle damage, serious personal injury, or death may result. Notice: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair All vehicles are equipped with a high pressure compact spare tire. The compact spare tire uses a narrow 4-inch wide rim, although the wheel diameter is usually one inch larger than the road wheels. Do not use the compact spare tire with standard tires, snow tires, wheel covers or trim rings. If such use is attempted, damage to these items or other parts of the vehicle may occur. Use the compact spare tire only on vehicles which offered the spare tire as the original equipment. CAUTION: To avoid serious personal injury, do not stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when Inflating any tire If beads are not seated If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. Periodically check inflation pressure. Maintain inflation pressure at 415 kPa (60 psi). The compact spare tire can be mounted and dismounted from the wheel using present tire changing equipment and procedures. As with other tires, completely seat the beads at 275 kPa (40 psi). The tire may then be safely inflated to 415 kPa (60 psi). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8514 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8515 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8516 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8521 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8527 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8528 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8529 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8534 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8539 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8540 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8545 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8546 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8547 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8552 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8570 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8571 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8572 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8577 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8582 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8583 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8596 Wheels: Specifications Maximum Radial Runout: Steel Wheel ......................................................................................................................................... ............................................. 1.01 mm (0.040 inch) Aluminum Wheels ............................................... ............................................................................................................................ 0.76 mm (0.030 inch) Maximum Lateral Runout: Steel Wheels ....................................................................................................................................... ............................................. 1.14 mm (0.045 inch) Aluminum Wheels ............................................... ............................................................................................................................ 0.76 mm (0.030 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description Wheels: Description and Operation General Description The factory installed tires and wheels are designed to operate with loads up to and including the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures, wheel alignment and driving techniques have an important influence on tire life. Heavy cornering, excessive rapid acceleration, and heavy braking will increase tire wear. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description > Page 8599 Wheels: Description and Operation Wheel Repair Description Wheel repairs that use welding, heating or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. Porosity in aluminum wheels can be repaired. Refer to ALUMINUM WHEEL POROSITY REPAIR. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > General Description > Page 8600 Wheels: Description and Operation Wheels Description Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if the wheel nuts won't stay tight, or if wheel nuts are heavily rusted. Wheels with excessive runout may cause objectionable vibrations. Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset, and mounting configuration. A wheel of improper size or type may affect wheel and bearing life, brake cooling, speedometer/odometer calibration, vehicle ground clearance, and tire clearance to the body and chassis. Steel wheels can be identified by a two or three-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal Wheels: Service and Repair Removal Penetrating oil is not effective in removing tight wheels. However, if it is used, apply sparingly to the center hole area of the wheel only. CAUTION: If penetrating all gets on the vertical surfaces between the wheel and the rotor or drum, it could cause the wheel to work loose as the vehicle is driven, resulting In a loss of control and an Injury accident. Wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force, such as hammering the wheel or tire, can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. REMOVAL PROCEDURE Using the following procedure, the wheel can be removed without damage. 1. Tighten all of the wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle from side to side. If this is not effective go to the next step. If this procedure is effective, go to Step 3. 2. Rock the vehicle from Drive to Reverse, allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal in order to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more person's body weight. If the wheel is still tight, repeat the procedure. 3. Raise the vehicle and suitably support the vehicle. 4. Remove the wheel cover. 5. Remove the wheel nuts. 6. Mark the location of the tire and wheel assembly to the hub assembly. 7. Clean the wheel nuts, studs and the wheel and brake chum or rotor mounting surfaces. CAUTION: Before Installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8603 Wheels: Service and Repair Installation INSTALLATION PROCEDURE 1. Install the cap on the aluminum wheel, if necessary. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. 3. Align the locating mark of the tire and the wheel with the hub assembly. CAUTION: Never use all or grease on studs or nuts. Tighten the wheel nuts with your fingers unto they are snug. Then, tighten the nuts (In the sequence shown) to the fastener tightening specification shown in SPECIFICATIONS. Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury, and property damage. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the wheel nuts. Tighten Tighten the wheel nuts in sequence to 140 Nm (100 ft. lbs.). 5. Install the wheel cover, if equipped. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8604 Wheels: Service and Repair Aluminum Wheel Hub Cap Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Use the following procedure in order to remove the hub cap: ^ Place a block of wood, approximately 50 mm (2 in) in diameter with a squared off end, against the back surface of the cap. ^ Strike the block of wood sharply with a hammer in order to remove the cap. INSTALLATION PROCEDURE 1. Install the hub cap using the following procedure: ^ Place the cap into position at the wheel opening. ^ Place a block of wood, at least 75 mm t3 in), on the diameter against the cap face. NOTICE: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. ^ Install the cap by striking the block of wood with a harmer. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8605 Wheels: Service and Repair Aluminum Wheel Porosity Repair 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Locate the leaking areas by inflating the tire to 275 kPa (40 psi) and dipping the tire and the wheel assembly into a water bath. 4. Mark the leak areas and remove the tire from the wheel. Refer to TIRE MOUNTING AND DISMOUNTING. 5. Scuff the inside of the rim surface at the leak area with 80 number grit sandpaper. Clean the area with general purpose cleaner. 6. Apply a 3 mm (1/8 inch) thick layer of adhesive/sealant to the leak area and allow six hours of drying time. 7. Mount the tire on the wheel. Pressurize the tire to 275 kPa (40 psi) and check for leaks. Refer to TIRE MOUNTING AND DISMOUNTING. CAUTION: To avoid serious personal Injury, do nor stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal Injury. 8. Adjust the tire pressure in order to meet specifications. 9. Balance the tire and the wheel assembly. 10. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8606 Wheels: Service and Repair Removal Penetrating oil is not effective in removing tight wheels. However, if it is used, apply sparingly to the center hole area of the wheel only. CAUTION: If penetrating all gets on the vertical surfaces between the wheel and the rotor or drum, it could cause the wheel to work loose as the vehicle is driven, resulting In a loss of control and an Injury accident. Wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force, such as hammering the wheel or tire, can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. REMOVAL PROCEDURE Using the following procedure, the wheel can be removed without damage. 1. Tighten all of the wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle from side to side. If this is not effective go to the next step. If this procedure is effective, go to Step 3. 2. Rock the vehicle from Drive to Reverse, allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal in order to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more person's body weight. If the wheel is still tight, repeat the procedure. 3. Raise the vehicle and suitably support the vehicle. 4. Remove the wheel cover. 5. Remove the wheel nuts. 6. Mark the location of the tire and wheel assembly to the hub assembly. 7. Clean the wheel nuts, studs and the wheel and brake chum or rotor mounting surfaces. CAUTION: Before Installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Installation INSTALLATION PROCEDURE 1. Install the cap on the aluminum wheel, if necessary. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. 3. Align the locating mark of the tire and the wheel with the hub assembly. CAUTION: Never use all or grease on studs or nuts. Tighten the wheel nuts with your fingers unto they are snug. Then, tighten the nuts (In the sequence shown) to the fastener tightening specification shown in SPECIFICATIONS. Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury, and property damage. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 4. Install the wheel nuts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8607 Tighten Tighten the wheel nuts in sequence to 140 Nm (100 ft. lbs.). 5. Install the wheel cover, if equipped. 6. Lower the vehicle. Aluminum Wheel Hub Cap Replacement REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Use the following procedure in order to remove the hub cap: ^ Place a block of wood, approximately 50 mm (2 in) in diameter with a squared off end, against the back surface of the cap. ^ Strike the block of wood sharply with a hammer in order to remove the cap. INSTALLATION PROCEDURE 1. Install the hub cap using the following procedure: ^ Place the cap into position at the wheel opening. ^ Place a block of wood, at least 75 mm t3 in), on the diameter against the cap face. NOTICE: Failure to hit the cap squarely without the load distributed evenly could result in permanent damage to the cap. ^ Install the cap by striking the block of wood with a harmer. 2. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Aluminum Wheel Porosity Repair 1. Raise and suitably support the vehicle. 2. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 3. Locate the leaking areas by inflating the tire to 275 kPa (40 psi) and dipping the tire and the wheel assembly into a water bath. 4. Mark the leak areas and remove the tire from the wheel. Refer to TIRE MOUNTING AND DISMOUNTING. 5. Scuff the inside of the rim surface at the leak area with 80 number grit sandpaper. Clean the area with general purpose cleaner. 6. Apply a 3 mm (1/8 inch) thick layer of adhesive/sealant to the leak area and allow six hours of drying time. 7. Mount the tire on the wheel. Pressurize the tire to 275 kPa (40 psi) and check for leaks. Refer to TIRE MOUNTING AND DISMOUNTING. CAUTION: To avoid serious personal Injury, do nor stand over tire when Inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal Injury. 8. Adjust the tire pressure in order to meet specifications. 9. Balance the tire and the wheel assembly. 10. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Aluminum Wheel Refinishing A protective clear or color coating is applied to the surface of original equipment cast aluminum wheels. A surface degradation condition can begin to develop if this clear coating is damaged or removed. This can happen at some automatic car wash facilities using aggressive silicon carbide tipped tire brushes in order to clean the white walls and the tires. Once the protective coating is damaged, exposure to caustic cleaners and/or road salt causes further surface degradation. The following procedure details how to strip, clean and coat the aluminum wheels that are affected by these conditions. Use the listed materials when completing this procedure. ^ Amchem Alumi Prep number 33 - stock number DX533 or the equivalent - cleaning and conditioning chemical for aluminum. ^ Amchem Alodine number 1001 - stock number DX50T or the equivalent-coating chemical for aluminum. ^ Ditzler Delclear Acrylic Urethane Clear - stock number DAU-75 or equivalent. ^ Ditzler Delthane Ultra-Urethane Additive - stock DXR-80 or equivalent. REMOVAL PROCEDURE 1. Remove the tire and the wheel assembly from the vehicle. Refer to WHEEL REMOVAL. 2. Match mark the tire for reinstallation of the outboard wheel weights after the recoating of the wheel. 3. Remove the outboard wheel weights. 4. Clean the inside and the outside of the wheel with a water base all purpose cleaner. 5. Remove grease or oil from the wheel with a solvent cleaner. SURFACE DAMAGE CAUTION: Do not use vehicle power to rotate the wheel while sanding to avoid personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8608 1. Sand over painted areas that do not require recoloring with number 400 (wet or dry) in order to promote adhesion of a clear coat. 2. Mount the tire and the wheel on a brake lathe and spin slowly. NOTICE: Do not use an abrasive coarser than 80 grit or wheel may be damaged. 3. Sand wheel with a backing block or a pad by holding the abrasive flat in order to the surface of the wheel and moving slowly back and forth from the center to the outer edge to remove damage. Use the following sandpaper grits in the order listed: 3.1. Sand with number 80 grit sandpaper. 3.2. Sand with number 150 grit sandpaper. 3.3. Sand with number 240 grit sandpaper. RE-COATING PROCEDURE CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal injury. 1. Clean the surface of the contaminants by washing the surface with soap and water. 2. Spray the wheel with Amchem number 33 or the equivalent. 3. Let the wheel soak for 1 to 3 minutes. 4. Rinse the wheel with water. Blow the wheel dry with compressed air. 5. Soak the wheel with Amchem number 1001 or the equivalent. 6. Let the wheel soak for 1 to 3 minutes. 7. Rinse the wheel with water. Blow the wheel dry with compressed air. 8. Mask off the tire. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 9. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or the equivalent using the following three coats. Refer to the labels for specific instructions: ^ First coat-light mist coat, let flash. ^ Second coat-light, let flash. ^ Third coat-heavy double wet coat. 10. Let the wheel dry for 24 hours (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALLATION PROCEDURE 1. Balance the tire and the wheel assembly. 2. Replace the original balance weights with nylon coated weights in order to avoid discoloration of the wheel. 3. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Clearcoat Damage to Aluminum Wheels UNPAINTED WHEELS 1. Remove the wheel and tire assembly from the vehicle. Refer to WHEEL REMOVAL. 2. Match mark the tire for reinstallation of the outboard wheel weights after the recoating of the wheel. 3. Remove the outboard wheel weights. 4. Clean the wheel inside and out with a water base all purpose cleaner. 5. Remove the grease or the oil with a solvent cleaner. 6. Sand over painted areas that do not require recoloring with number 400 (wet or dry) to promote adhesion of clear coat. CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 7. Apply the chemical stripper. 8. Allow the stripper to penetrate the coating. 9. Use a small 1/4 inch-detail brush dipped in stripper in order to apply the material around the perimeter and the spoke-like areas. 10. Remove the stripper following the manufacturer's recommendations. CAUTION: Do not use vehicle power to rotate the wheel walls sanding to avoid personal Injury. 11. Sand the wheel with 240 grit while rotating the wheel on a slow spinning brake lathe or by mounting on the vehicle and spinning by hand. This will restore the machined appearance and promote adhesion. CAUTION: Use of rubber gloves and eye protection Is necessary to prevent personal injury. 12. Clean the surface of the contaminants by washing the surface with soap and water. 13. Spray the wheel with Amchem number 33 or the equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Removal > Page 8609 14. Let the wheel soak for 1 to 3 minutes. 15. Rinse the wheel with water. Blow the wheel dry with compressed air. 16. Soak the wheel with Amchem number 1001 or the equivalent. 17. Let the wheel soak for 1 to 3 minutes. 18. Rinse the wheel with water. Blow the wheel dry with compressed air. 19. Mask off the tire. 20. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or the equivalent using the following three coats. Refer to the labels for specific instructions. ^ First coat-light mist coat, let flash. ^ Second coat-light, let flash. ^ Third coat-heavy double wet coat. 21. Let the wheel dry for 24 hours (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALLATION PROCEDURE 1. Balance the wheel and the tire assembly. 2. Replace the original balance weights with nylon coated weights in order to avoid discoloration of the wheel. 3. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT WHEEL BEARINGS AND/OR HUB REMOVAL PROCEDURE ^ Tools Required: J 28733-B Front Hub Spindle Remover 1. Remove the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in Drive Axles, Bearings and Joints. 2. Remove brake caliper bolts and support caliper. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 3. Remove the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Remove the bolts (1) from the hub and bearing assembly (3). 5. Remove the hub and bearing assembly (1) from the steering knuckle (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8615 1. Install the hub and bearing assembly (1) into the steering knuckle (2). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 2. Install the hub and bearing bolts (1) and washers (2). Tighten Tighten the bolts to 95 Nm (70 ft. lbs.). 3. Install the rotor. Refer to ROTOR REPLACEMENT in HYDRAULIC BRAKES. 4. Install the brake caliper and bolts. Refer to BRAKE CALIPER REPLACEMENT in BRAKES. 5. Install the drive axle. Refer to WHEEL DRIVE SHAFTS REPLACEMENT in DRIVE AXLES, BEARINGS AND JOINTS. 6. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 8616 Wheel Bearing: Service and Repair Rear REAR HUB AND/OR BEARINGS REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the brake drum. Refer To BRAKE DRUM REPLACEMENT. 4. Remove the hub and bearing assembly (4) from the axle (2). The top rear attaching bolt (5) and nut (1) will not clear the brake shoe (3) when removing the hub and bearing assembly. Partially remove the hub and bearing assembly prior to removing this bolt. 5. Disconnect the rear ABS wheel speed sensor wire connector. INSTALLATION PROCEDURE 1. Connect the rear ABS wheel speed sensor wire connector. 2. Install the hub and bearing assembly (4). Position the top rear attaching bolt (5) in the hub and bearing assembly prior to the installation in the axle assembly (2). Tighten Tighten the hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 4. Install the tire and wheel assemblies. Refer to WHEEL REMOVAL. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Specifications Wheel Cover: Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Axle Nut: Specifications Drive Axle Nut 200 Nm (144 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 8625 Axle Nut: Specifications Rear Hub and Bearing to Axle Bolts 60 Nm (44 ft.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: Recalls Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 8639 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 8645 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: All Technical Service Bulletins Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 8655 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > NHTSA97V219000 > Nov > 97 > Recall 97V219000: Wheels/Brake Pipe Inspection Wheel Fastener: All Technical Service Bulletins Recall 97V219000: Wheels/Brake Pipe Inspection Year: 1998 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 24 Summary: Vehicle Description: Passenger vehicles. The wheel lug nuts were not tightened securely resulting in a fracture of the wheel studs. The wheel could separate from the vehicle. If the vehicle were in motion, a vehicle crash could result. Dealers will inspect and replace the brake pipe. Dealer notification began November 21, 1997. All vehicles are still at dealers. No owners are involved. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Tightening Torque All Wheel Nuts ..................................................................................................................................... ............................................... 140 N.m (100 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 8663 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 8664 Wheel Fastener: Description and Operation All models use metric wheel nuts and wheel studs. The nut will have the word metric stamped on the face and the stud will have the letter M stamped into the threaded end. The word metric is stamped on the head. The thread size of the metric wheel nuts and wheel studs are M 12 x 1.5 This signifies: ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters per thread If a broken stud is found, refer to FRONT SUSPENSION or DRIVE AXLE for the replacement procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension REMOVAL PROCEDURE ^ Tools Required: J 6627-A Wheel Stud Remover - J 28733-A Front Hub Spindle Remover 1. Remove the hub and bearing assembly (2). Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 2. Remove the wheel stud (1) from the hub and bearing assembly using the J 6627-A. 3. Discard the stud. INSTALLATION PROCEDURE 1. Install the new wheel stud (1) into the hub and bearing assembly (2). 2. Install the flat washers (3) and nut, flat side down, onto the wheel stud. Tighten until the wheel stud is fully seated. 3. Install the hub and bearing assembly. Refer to WHEEL BEARING AND WHEEL HUB REPLACEMENT. 4. Check the front wheel alignment. Refer to MEASURING WHEEL ALIGNMENT (FRONT ALIGNMENT ANGLES). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 8667 Wheel Fastener: Service and Repair Rear Suspension REMOVAL PROCEDURE ^ Tools Required: J 6627-A Wheel Stud Remover 1. Remove the tire and the wheel assembly. Refer to WHEEL REMOVAL. 2. Remove the brake drum. Refer to BRAKE DRUM REPLACEMENT. NOTICE: Do not hammer on brake drum as damage to the bearing could result. 3. Remove the wheel stud (2) using the J 6627-A. 4. Discard the wheel stud (2). INSTALLATION PROCEDURE 1. Install the new stud from the back side of the hub. 2. Install the four flat washers (1) on the hub. 3. Install the wheel nut (2) with the flat side toward the washers (1). 4. Tighten the nut (2) until the stud head is properly seated in the hub flange. 5. Remove the nut (2) and the washers (1). 6. Install the brake drum. Refer to BRAKE DRUM REPLACEMENT. 7. Install the tire and the wheel assembly. Refer to WHEEL INSTALLATION. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications A/C Accumulator Torque Specifications A/C Accumulator Torque Specifications A/C Accumulator Bracket Nut 89 in.lb A/C Accumulator Retaining Clamp Bolt 71 in.lb A/C Accumulator Bracket Bolt 44 in.lb A/C Accumulator Inlet Fitting 18 ft.lb A/C Accumulator Outlet Fitting 18 ft.lb A/C Accumulator Tube to Evaporator 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8672 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8673 Accumulator HVAC: Description and Operation Downstream of the evaporator outlet pipe, the sealed accumulator assembly functions as a liquid/vapor separator. It receives refrigerant vapor, along with some liquid refrigerant and refrigerant oil from the evaporator. It allows only refrigerant vapor and oil to pass on to the compressor. At the bottom of the accumulator is the desiccant bag. It acts as a drying agent for moisture that may have entered the system. An oil bleed hole is located near the bottom of the accumulator outlet pipe to provide an oil return path to the compressor. If the system is open to air for an extended period of time (due to a front-end collision, removed parts, etc.) replace the accumulator. The desiccant bag will be saturated with moisture. The accumulator is serviced by replacement only. The accumulator is located in the right hand corner of the engine compartment and is attached to the front of dash. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8674 Accumulator HVAC: Service and Repair The accumulator assembly service replacement part includes O-rings (as necessary) for connections. The desiccant within the shell is NOT serviced separately - it is part of the sealed accumulator assembly. The accumulator assembly should be replaced ONLY when the shell is perforated and a refrigerant leak is found, or the system has been open to the atmosphere for an extended period. Accumulators do not require periodic replacement due to the following changes: ^ Use of improved desiccant. ^ Use of improved hose material and increased use of metal lines, both of which reduces the ability of moisture to enter the refrigerant system. Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Cruise control stepper motor bracket, and position aside. (if equipped). 4. Refrigerant lines at the accumulator. Discard O-ring seals. 5. Clamp on accumulator bracket and accumulator. Install or Connect 1. Accumulator and bracket clamp. Tighten ^ Screw to 8 N.m (71 lb in). Important ^ Add required amount of new refrigerant oil. 2. Refrigerant lines at the accumulator using new O-ring seals. Tighten ^ Fitting to 24 N.m (18 lb ft). 3. Cruise control stepper motor bracket. 4. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8675 5. Evacuate and charge the A/C system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations HVAC Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 8680 (2 Of 2) The vacuum actuators are located under the instrument panel and attached to the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator Air Door Actuator / Motor: Service and Repair Air Inlet (Recirculation) Vacuum Actuator HVAC Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8683 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8684 HVAC Module - Top And Left View Remove or Disconnect 1. Negative battery cable. 2. Instrument panel trim pad. 3. Passenger side SIR module. 4. Vacuum hose from actuator. 5. Clip attaching actuator to the module. 6. Actuator arm from the valve. 7. Actuator from the vehicle. Install or Connect 1. Actuator arm to the valve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8685 2. Actuator to the module, snap into place. 3. Vacuum hose to the actuator. 4. Passenger side SIR module. 5. Instrument panel trim pad. 6. Negative battery cable Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8686 Air Door Actuator / Motor: Service and Repair Air Distribution Valve Actuators Mode Valve Vacuum Actuator Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8687 (2 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Left sound insulator. 3. Instrument panel trim pad. 4. Air distribution duct. 5. Actuator and actuator rod from module. 6. Vacuum hoses from actuator. 7. Vacuum actuator from the vehicle. Install or Connect 1. Vacuum actuator from below. 2. Vacuum hoses to actuator. 3. Actuator rod to module (from above). 4. Air distribution duct. 5. Instrument Panel trim pad. 6. Left sound insulator. 7. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Defrost Valve Vacuum Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8688 Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Inlet (Recirculation) Vacuum Actuator > Page 8689 (2 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Instrument panel trim pad. 3. Passenger side SIR module. 4. Vacuum hose from actuator. 5. Clip attaching actuator to the module. 6. Actuator arm from the valve. 7. Actuator from the vehicle. Install or Connect 1. Actuator arm to the valve. 2. Actuator to the module, snap into place. 3. Vacuum hose to the actuator. 4. Passenger side SIR module. 5. Instrument Panel trim pad. 6. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Locations Air Door Cable: Locations The temperature control cable is attached to the right of the HVAC module heater case. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Locations > Page 8693 Air Door Cable: Service and Repair Remove or Disconnect 1. Right sound insulator panel. 2. Cable from module. 3. Instrument panel trim plate. 4. Heater and A/C control and pull rearward. 5. Cable from heater and A/C control. Install or Connect 1. Cable to heater and A/C control. 2. Heater and A/C control to Instrument Panel. Tighten ^ Screws to 2 N.m (18 lb in). 3. Instrument Panel Trim plate. 4. Cable to module. 5. Right sound insulator panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Air Distribution Ducts and Outlet Torque Specifications Air Distribution Ducts and Outlet Torque Specifications Rear Floor Duct Or Outlet Nut 9 ft.lb Rear Floor Outlet Screw 53 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > Rear Floor Duct Air Duct: Locations Rear Floor Duct The rear floor outlet duct is located under the console and floor carpeting. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > Rear Floor Duct > Page 8699 Air Duct: Locations Defroster Duct Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > Rear Floor Duct > Page 8700 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations > Page 8701 Air Duct: Description and Operation A system of ducts and outlets directs air from the HVAC module to the passenger compartment. In cases of poor air output, defroster, heater, A/C and vent ducts should be checked for obstructions or other objects which may have fallen into the ducts, air inlet, or cowl panel screen. Vehicles are equipped with side window defoggers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Front Air Duct: Service and Repair Front It is necessary to partially remove portions of the Instrument Panel assembly to gain access to the air distribution ducts as required. Remove or Disconnect 1. Negative battery cable. 2. Instrument panel trim. 3. Air distribution duct. Install or Connect 1. Air distribution duct. 2. Instrument Panel trim. 3. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Front > Page 8704 Air Duct: Service and Repair Rear Floor Remove or Disconnect 1. Console. 2. Floor carpeting partially removed to rear of front seat. 3. Rear floor duct or outlet. Install or Connect 1. Rear floor duct or outlet. Tighten ^ Nut to 2 N.m (9 lb ft). 2. Floor carpeting. 3. Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor Torque Specifications Blower Motor Torque Specifications Blower Motor Screws 44 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan Assembly Blower Motor: Locations Blower Motor and Fan Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan Assembly > Page 8710 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan Assembly > Page 8711 The blower motor and fan are located in the lower right corner of the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan Assembly > Page 8712 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8713 Blower Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8714 Blower Motor: Description and Operation The blower moves air across the HVAC module case and through the evaporator. The evaporator dehumidifies the air and the resulting moisture is expelled through a drain at the front of dash.The blower speed is controlled by the position of the blower speed switch and dictated by a resistor in the electrical circuit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8715 Blower Motor: Service and Repair Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8716 (2 Of 2) The blower motor and fan are serviced as an assembly only. Remove or Disconnect 1. Negative battery cable. 2. Right sound insulator. 3. Electrical connections at blower motor. 4. Blower motor retaining screws. 5. Blower motor and fan assembly. Install or Connect 1. Blower motor and fan assembly. 2. Retaining screws. Tighten ^ Screws to 5 N.m (45 lb in). 3. Electrical connections. 4. Right sound insulator. 5. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Torque Specifications Blower Motor Resistor Torque Specifications Blower Motor Resistor Screws 9 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 8720 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 8721 Blower Resistor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 8722 Blower Motor Resistor: Service and Repair Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 8723 (2 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Right sound insulator. 3. Blower motor Refer to Blower Motor and Fan Assembly. 4. Cut portion of dash mat to gain access to the rear resistor screw. 5. Electrical connections at blower resistor. 6. Blower resistor screws and resistor. Install or Connect 1. Blower resistor and resistor screws. Tighten ^ Screws to 1 N.m (9 lb in). 2. Replace portion of dash mat cut in removal procedure. 3. Electrical connections at blower resistor. 4. Blower motor. Tighten ^ Screws to 5 N.m (45 lb in). 5. Right sound insulator. 6. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. Instrument Panel trim plate. Refer to Trim Plate in instrument Panel, Gauges and Console. 3. Control assembly screws and pull control assembly away from the instrument Panel. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. Tighten ^ Screws fully driven, seated and not stripped. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. Tighten ^ Screws to 2 N.m (18 lb in). 5. Instrument Panel trim plate. 6. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor Clutch Air Gap Specification A/C Compressor Clutch Air Gap Specification A/C Clutch Air Gap 0.015 - 0.020 in Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8731 Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8732 A/C Compressor Clutch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8733 Compressor Clutch: Service and Repair Removing Shaft Nut Clutch Plate And Hub Assembly Removal Remove or Disconnect 1. Clamp the holding fixture J 34992 in a vise and attach compressor to holding fixture with thumb screws J 34992-1. 2. Keep the clutch hub and drive plate assembly from turning by using the clutch hub holding tool J 33027-A. Remove the shaft nut using shaft nut socket J 33022. 3. Thread the Clutch Plate and Hub Assembly Remover J 33013-B into the hub. Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch plate and hub assembly. 4. Remove the shaft key and retain for reassembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8734 Shaft Key, Clutch Plate/Hub Installation Installing Clutch Plate & Hub Assembly Install or Connect 1. Install the shaft key into the hub key groove. Allow the key to project approximately 3.2 mm (1/8") out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Be sure the frictional surface of the clutch plate and the clutch rotor are clean before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway and place the clutch plate and the hub assembly onto the compressor shaft. NOTICE: Do not drive or pound on the clutch hub or shaft. Internal damage to compressor may result. 4. Remove the J 33013-B remover-installer center screw and reverse the body direction on the center screw as shown in the illustration. 5. Install the clutch plate and hub installer J 33013-B with bearing as shown in the illustration. The body of the J 33013-B installer should be backed off sufficiently to allow the center screw to be threaded onto the end of the compressor shaft. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8735 6. Hold the center screw with a wrench. Tighten the hex portion of the installer J 33013-B body to press the hub onto the shaft. Tighten the body several turns, remove the installer and check to see that the shaft key is still in place in the keyway before installing the clutch plate and hub assembly to its final position. The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0.40-0.50mm (0.015-0.020"). ^ If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will assume the position as shown in the illustration and will break the clutch hub. 7. Remove installer J 33013-B, check for proper positioning of the shaft key (even or slightly above the clutch hub). Install the shaft nut. Hold the clutch plate and hub assembly with clutch hub holding tool J 33027-A and using shaft nut socket J 33022, tighten the nut against the crankshaft shoulder to 16.5 N.m (12 lbs.ft.) torque, using a torque wrench. 8. Spin the pulley rotor by hand to see that the rotor is not rubbing the clutch drive plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Remove Compressor Clutch Bearing: Service and Repair Remove Removing Pulley Rotor & Bearing Assembly Retaining Ring Installing Pulley Rotor/Bearing Puller Guide Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Remove > Page 8741 Removing Pulley Rotor And Bearing Assembly Pulley Rotor Bearing Removal Remove or Disconnect 1. Remove the clutch plate and hub assembly as described previously. 2. Remove rotor and bearing assembly retaining ring, using snap ring pliers J 6083. 3. Install pulley rotor and bearing puller guide J 33023-A to the front head and install J 33020 pulley rotor and bearing puller down into the inner circle of slots in the rotor. Turn the J 33020 puller clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor. 4. Hold the J 33020 puller in place and tighten the puller screw against the puller guide to remove the pulley rotor and bearing assembly. 5. To prevent damage to the pulley rotor during bearing removal the rotor hub must be properly supported. Remove the forcing screw from J 33020 puller and, with the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks as shown in the illustration. 6. Drive the bearing out of the rotor hub with rotor bearing remover J 9398-A and J 29886 universal handle. NOTICE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Remove > Page 8742 Compressor Clutch Bearing: Service and Repair Replace Installing Pulley Rotor Bearing Staking Bearing In Rotor Hub Bore Bearing Staked In Place Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Remove > Page 8743 Installing Pulley Rotor And Bearing Assembly Removing Pulley Rotor & Bearing Assembly Retaining Ring Install or Connect 1. Place the pulley rotor on the J 21352-A support block to fully support the rotor hub during bearing installation. NOTICE: Do Not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Align the new bearing squarely with the hub bore and using puller and bearing installer J 9481-A with universal handle J 29886, drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing if used as shown. 3. Place bearing staking guide J 33019-1 and bearing staking pin J 33019 in the hub bore as shown in the illustration. Shift the rotor and bearing assembly on the J 21352-A support block to give full support of the hub under the staking pin location. A heavy-duty rubber band may be used to hold the stake pin in the guide, and the stake pin should be properly positioned in the guide after each impact on the pin. 4. Using care to prevent personal injury, strike the staking pin with a hammer until a metal stake, similar to the original, is formed down to but not touching the bearing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Remove > Page 8744 The stake metal should not contact the outer face of the bearing to prevent the possibility of distorting the outer race. Stake three (3) places 120° apart as shown in the illustration. 5. With the compressor mounted to the J 34992 holding fixture, position the rotor and bearing assembly on the front head. 6. Position the J 33017 pulley rotor and bearing installer and J 33023-A puller pilot directly over the inner race of the bearing. 7. Position puller crossbar J 8433-1 on the puller pilot J 33023-A and assemble the two J 34992-2 through bolts and washers through the puller bar slots and thread them into the J 34992 holding fixture. The thread of the through bolts should engage the full thickness of the holding fixture. 8. Tighten the center screw in the J 8433-1 puller crossbar to force the pulley rotor and bearing assembly onto the compressor front head. Should the J 33017 pulley rotor and bearing installer slip off direct in-line contact with the inner face of the bearing, loosen the J 8433-3 center forcing screw and realign the installer and pilot so that the J 33017 installer will properly clear the front head. 9. Install rotor and bearing assembly retainer ring, using snap ring pliers J 6083. 10. Reinstall clutch plate and hub assembly as described previously. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 8748 Compressor Clutch Coil: Service and Repair Clutch Coil Assembly Removal Installing Clutch Coil Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 8749 Staking Clutch To Front Head Details Of Stakes In Front Head For Clutch Coil Remove or Disconnect 1. Perform Steps 1 through 4 of "Clutch Rotor and/or Bearings" removal procedure. Mark clutch coil terminal location on compressor front head. 2. Install J 33023-A puller pilot on front head of compressor. Also install J 8433-1 puller crossbar with J 33025 puller legs as shown in the illustration. 3. Tighten J 8433-3 forcing screw against the puller pilot to remove the clutch coil. Install or Connect 1. Place the clutch coil assembly on the front head with the terminals positioned at the "marked" location. 2. Place the J 33024 clutch coil installer over the internal opening of the clutch coil housing and align installer with the compressor front head. 3. Center the J 8433-1 puller crossbar in the countersunk center hole of the J 33024 clutch coil installer. Install the J34992-2 through bolts and washers through the crossbar slots and thread them, into the holding fixture J 34992 to full fixture thickness. 4. Turn the center forcing screw of the J 8433-1 puller crossbar to force the clutch coil onto the front head. Be sure clutch coil and J 33024 installer stay "in-line" during installation. 5. When coil is fully seated on the front head, use a 1/8" diameter drift punch and stake the front head at three (3) places 120° apart, to ensure clutch coil remaining in position. ^ Stake size should be only one half the area of the punch tip and only approximately 0.28-035mm (0.010-0.015") deep. 6. Install rotor and bearing assembly and the clutch plate and hub assembly according as described previously. 7. Install shaft nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations > Page 8753 Compressor Control Valve Assembly: Service and Repair V-5 Compressor Tools Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station. J 5403 Internal Snap Ring Pliers. Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Raise vehicle. 4. Control valve retaining ring using J 5403. 5. Control valve. Install or Connect 1. Control valve. 2. Control valve retaining ring using J 5403. 3. Lower vehicle. 4. Evacuate and recharge refrigerant system. 5. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations > Page 8757 Compressor Shaft Seal: Testing and Inspection Seal Leak Detection A shaft seal should not be changed because of small amounts of oil found on an adjacent surface. The seal is designed to leak some oil for lubrication purposes. A shaft seal should be changed only when a large amount of sprayed oil is found, and only after actual refrigerant leakage is found by using an approved leak detector, J 39400 or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations > Page 8758 Compressor Shaft Seal: Service and Repair Seal Leak Detection A shaft seal should not be changed because of small amounts of oil found on an adjacent surface. The seal is designed to leak some oil for lubrication purposes. A shaft seal should be changed only when a large amount of sprayed oil is found, and only after actual refrigerant leakage is found by using an approved leak detector, J 39400 or equivalent. Removing Or Installing Shaft Seal Retaining Ring Removing Shaft Seal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations > Page 8759 Removing Shaft Seal O-Ring Compressor Shaft Seal Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. Loosen and reposition compressor in mounting brackets. 3. Remove clutch plate and hub assembly from compressor as described in minor repairs. 4. Remove the shaft seal retainer ring, using snap ring pliers J 5403. 5. Thoroughly clean inside of compressor neck area surrounding the shaft. tile exposed portion of the seal. the shaft itself and O-ring groove. Any dirt or foreign material getting into compressor may cause damage. 6. Fully engage the knurled tangs of seal remover-installer J2312-A into the recessed portion of the seal by turning the handle clockwise. Remove the seal from the compressor with a rotary-pulling motion. Discard the seal. The handle should be hand-tightened securely. Do not use a wrench or pliers. 7. Remove and discard the seal O-ring from the compressor neck using O-ring remover J 9553-01. 8. Recheck the shaft and inside of the compressor neck for dirt or foreign material and be sure these areas are perfectly clean before installing new parts. Clean 1. Thoroughly clean seal O-ring groove in front head. NOTICE: Seals should not be re-used. Always use a new specification service seal kit. Be sure that the seal to be installed is not scratched or damaged in any way. Make sure that the seal is free of lint and dirt that could damage the seal surface or prevent sealing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations > Page 8760 Installing Shaft Seal O-Ring Lip Seal Installed On Seal Protector Removing Or Installing Shaft Seal Retaining Ring Install or Connect 1. Dip the new seal O-ring in clean 525 viscosity refrigerant oil and assemble onto O-ring installer J 33011. "New". Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Locations > Page 8761 2. Insert the O-ring installer J 33011 into the compressor neck until the installer "bottoms." Lower the moveable slide of the O-ring installer to release the O-ring into the seal O-ring lower groove. (The compressor neck top groove is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring and remove the installer. 3. Dip the new seal in clean 525 viscosity refrigerant oil and assemble seal to Seal Installer J 23128-A, by turning handle clockwise. The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that flared-out side of lip seal is facing and installed towards the compressor. Install shaft seal protector J 34614 on the lip seal. Place the seal protector J 34614 over end of compressor shaft, and slide the new seal onto the shaft with a rotary motion until it stops. Take care not to dislodge the O-ring. Be sure the seal makes good contact with the O-ring. Disengage the installer from the seal and remove the installer J 23128-A and the shaft seal protector J 34614. NOTICE: Handling and care of seal protector is important. If seal protector is nicked or the bottom flared. the new seal may be damaged during installation. 4. Install the new seal retainer ring with its flat side against the seal, using snap-ring pliers J 5403. Use the sleeve from O-ring installer J 33011 to press in on the seal retainer ring so that it snaps into its groove. 5. To leak test. install compressor leak test fixture J 39893 on rear head of compressor and connect gage charging lines using J 39500-GM Refrigerant Recovery System or equivalent. Pressurize suction and high-side of compressor with R134a Refrigerant. Temporarily install the shaft nut and, with the compressor in horizontal position. rotate the compressor shaft in normal direction of rotation several turns by hand. Leak test the seal area and correct any leak found. Recover refrigerant. Remove shaft nut. 6. Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck. 7. Install the clutch plate and hub assembly as described in minor repair procedures. 8. Reinstall the compressor, belt and tighten bracket. 9. Evacuate and charge the refrigerant system using J 39500-GM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations Compressor Clutch Diode HVAC: Locations In the engine harness approximately 21 cm (8 in) from the A/C compressor clutch connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C COMPRESSOR CONTROL RELAY Fuse Block Details The A/C Compressor Control Relay is located in the Engine Compartment Fuse/Relay Center. The Engine Compartment Fuse/Relay Center is located in the left front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8768 Compressor Clutch Relay: Description and Operation The A/C compressor control relay is designed to disengage the A/C compressor clutch momentarily during start-up on a warm engine. The relay is PCM controlled. Voltage is supplied from the A/C power feed circuit and the PCM completes the ground to close a set of normally opened points. This turns the compressor clutch ON. The PCM opens the ground circuit when an engine run signal is sensed with coolant temperature at a specified amount. On a warm engine start-up, a time delay of about 3 seconds allows the engine speed to stabilize before the compressor engages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Compressor and Condenser Hose Bolt to Rear of Compressor 24 ft.lb A/C Condenser Inlet From Evaporator Fitting Nut 12 ft.lb A/C Condenser Outlet Fitting Nut 12 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8772 Condenser HVAC: Description and Operation The condenser in front of the radiator is made up of coils which carry the refrigerant. Cooling fins provide rapid transfer of heat. Air passing through the condenser cools the high-pressure, high-temperature refrigerant vapor, causing it to condense into a liquid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8773 Condenser HVAC: Service and Repair Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 3. Upper closeout panel. 4. Hood latch from mounting plate. 5. Right and left headlamp assemblies. 6. Raise vehicle. 7. Disconnect forward SIR sensor harness. 8. Lower vehicle. 9. Right radiator mount. 10. Hood latch support bracket & forward sensor w/harness. 11. Compressor hose and evaporator line from the condenser, discard O-rings. Important ^ Use back-up wrench to prevent twisting of block fitting. 12. Condenser. Install or Connect 1. Condenser in vehicle. 2. Compressor hose and evaporator line to condenser, using new O-rings. Tighten ^ Nuts to 16 N.m (12 lb ft). Important ^ Use back-up wrench to prevent twisting of block fitting. 3. Hood latch support bracket & forward sensor w/harness. 4. Right radiator mount. 5. Raise vehicle. 6. Connect forward SIR sensor harness. 7. Lower vehicle. 8. Right and left headlamp assemblies. 9. Hood latch assembly and adjust. 10. Upper closeout panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8774 11. Recharge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 12. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications Control Assembly: Specifications Heater and A/C Control Torque Specifications Heater and A/C Control Torque Specifications Heater And A/C Control Screws 18 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Heater A/C and Rear Defogger Control Assembly Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Heater A/C and Rear Defogger Control Assembly > Page 8780 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Heater-A/C and Rear Defogger Control Assembly Control Assembly: Diagrams Heater-A/C and Rear Defogger Control Assembly Heater - A/C And Rear Defogger Control Assembly (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Heater-A/C and Rear Defogger Control Assembly > Page 8783 Heater - A/C And Rear Defogger Control Assembly (C2) Heater - A/C And Rear Defogger Control Assembly (C3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Heater-A/C and Rear Defogger Control Assembly > Page 8784 Heater - A/C And Rear Defogger Control Assembly (C1) (W/C49) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 8785 Control Assembly: Description and Operation The five modes of the base heater system (Vent, Heat, Defrost, Bi-Level and Blend) are controlled by the functional assemblies within the heater module. These assemblies are defined below: 1. Motor and Fan Assembly (Blower). ^ Provides and regulates air flow from the air inlet for further processing and or distribution. 2. Heater Core. ^ Transfers heat from engine coolant to inlet air, thus heating the inlet air. 3. Temperature Valve. ^ Regulates the amount of air passing through the heater core, thus controlling the temperature and mix of heated and ambient air. 4. Mode and Defrost and Heat Valves. ^ Regulate the flow and distribution of processed air to the distribution ducts. The operation of these assemblies is controlled by the levers and switch on the control assembly. The temperature lever operates a cable and the mode lever operates a vacuum control to select the appropriate mode. Four blower speeds are controllable in all functional modes by the switch on the control assembly. Side window defogging is provided by ducts in the outboard corners of the instrument panel. Maximum air flow from these vents will be in the Heater mode with reduced air flow in the Defrost mode. In the Heat, Bi-Level, Vent, Blend and Defrost mode outside air is driven by the blower to the temperature valve which, dependent upon its position as controlled by be operator, distributes all or some portion of the inlet air through the heater core. The air is heated, mixed and then directed into either the defroster duct, vent or the heater outlet depending on the position of the mode defrost and heat valves. A small amount of air is bled to the side window defogger system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 8786 Control Assembly: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. Instrument panel trim plate. Refer to Trim Plate in instrument Panel, Gauges and Console. 3. Heater and A/C control retaining screws and pull heater and A/C control away from the instrument panel. 4. Electrical and vacuum connections. 5. Temperature control cable from heater and A/C control. Install or Connect 1. Temperature control cable to heater and A/C control. 2. Electrical and vacuum connections. 3. Heater and A/C control and retaining screws to instrument panel. Tighten ^ Screws to 2 Nm (18 lb in). 4. Instrument Panel trim plate. 5. Negative battery cable. Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation The blower speed is controlled by a knob which actuates a switch. The blower circuit is open in the OFF mode. In all other modes the blower has 4 speeds to control the amount of air that flows through the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8798 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8799 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8805 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 8806 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 8807 Evaporator Core: Specifications A/C Accumulator Tube to Evaporator 18 ft.lb A/C Condenser Inlet From Evaporator Fitting Nut 12 ft.lb A/C Evaporator Clamp Screw 9 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Blower Motor and Evaporator Evaporator Core: Description and Operation Blower Motor and Evaporator The blower moves air across the HVAC module case and through the evaporator. The evaporator dehumidifies the air and the resulting moisture is expelled through a drain at the front of dash.The blower speed is controlled by the position of the blower speed switch and dictated by a resistor in the electrical circuit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Blower Motor and Evaporator > Page 8810 Evaporator Core: Description and Operation Refrigeration System The evaporator is a device which cools and dehumidifies the air before it enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion tube, becomes a low-pressure liquid, and then enters the evaporator. The heat in the air passing through the evaporator core is transferred to the cooler surface of the core, thereby cooling the air. As the process of heat transfer from the air to the evaporator core surface is taking place, any moisture (humidity) in the air condenses on the outside surface of the evaporator core and is drained off as water. The evaporator is located inside the HVAC module at the front of dash. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8811 Evaporator Core: Service and Repair HVAC Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8812 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8813 Tool Required: J 39500 R-l34a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Drain cooling system. 4. Raise vehicle. 5. Heater hoses from heater core. 6. Evaporator fittings from the evaporator and discard O-ring seals. 7. Moisture drain tube from HVAC module. 8. Lower vehicle. 9. Instrument panel and console. 10. Heater outlet cover and heater core cover. ^ There is a mounting screw located in a recess in the center of the cover. 11. Heater core mounting clamps and heater core. 12. Heater core shroud and evaporator core. ^ There is a mounting screw located at the middle of the front of dash. Install or Connect 1. Evaporator. Tighten ^ Screws to 1 Nm (9 lb in). 2. Heater core should heater core and heater core mounting clamp. Tighten ^ Screw to 1 Nm (9 lb in). 3. Heater core cover and heater outlet cover. Tighten ^ Screws to 1 Nm (9 lb in). 4. Instrument panel and console. 5. Raise vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 8814 6. Moisture drain tube to the HVAC module. 7. Evaporator fittings to evaporator using new O-ring seals lubricated in clean 525 viscosity refrigerant oil. Tighten ^ Fittings to 24 Nm (18 lb ft). 8. Heater hoses to heater core. 9. Lower vehicle. 10. Fill cooling system and check for leaks. 11. Evacuate and charge the A/C system. 12. Negative battery cable. Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations Evaporator Tube And Accumulator Tube The expansion tube (orifice) is located at the condenser to evaporator line connection in the condenser. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8818 Expansion Block/Orifice Tube: Description and Operation The expansion tube is a plastic assembly containing a fixed diameter tube with a mesh filter screen at either end. It is located at the condenser outlet tube. The fixed diameter tube creates a restriction to the high-pressure liquid refrigerant in the liquid line, metering the flow of refrigerant to the evaporator as a low-pressure liquid. When the engine is turned OFF with the A/C system operating, the refrigerant in the system will flow from the high-pressure side of the expansion tube (orifice) to the low-pressure side until the pressure is equalized. This may be detected as a faint sound of liquid flowing (hissing) for 30 to 60 seconds and is a normal condition. When system diagnostics indicate a restricted expansion tube, it may not be necessary to replace it. Metal chips, flakes or slivers found on the screen may be removed with compressed air and the expansion tube may be reused if: ^ The plastic frame is not broken. ^ The brass expansion tube is not damaged or plugged. ^ The screen material is not torn. ^ The screen is not plugged with fine gritty material. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8819 Expansion Block/Orifice Tube: Service and Repair Evaporator Tube And Accumulator Tube Important ^ Different designs and colors of orifice tubes may have been used in past production vehicles. When replacing an orifice tube, compare its design to the replacement part for correct orifice tube selection. The different styles of orifice tubes ARE NOT INTERCHANGEABLE. Tools Required: J 26549-E Expansion Tube Remover J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Upper closeout panel. 3. Connection at condenser. Discard O-ring seals. 4. Evaporator line from clip on body side rail. 5. Carefully remove the expansion tube with needle-nose pliers, or tool J 26549-E. ^ In the event that difficulty is encountered during the removal of a restricted or plugged expansion tube (orifice tube), the following procedure is recommended: A. Remove as much of any impacted residue as possible. B. Carefully apply heat with heat gun (hair drier, epoxy drier or equivalent) approximately 7 mm (1/4 inch) from dimples on inlet pipe. Do not overheat pipe. C. While applying heat, use expansion tube removal tools or J 26549-E to grip the expansion tube. Use a turning motion along with a push-pull motion to loosen and remove to the impacted expansion tube. Install or Connect 1. New expansion tube. 2. Evaporator line to clip. 3. Using new O-ring seals, assemble evaporator tube/condenser connection. Tighten ^ Nut to 16 N.m (12 lb ft). 4. Upper closeout panel. 5. Evacuate and charge the system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 8824 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 8825 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8826 Heater Core: Specifications Heater Core Torque Specifications Heater Core Torque Specifications Heater Core Cover Screws 9 in.lb Heater Core Shroud Screws 9 in.lb Heater Core Strap Screws 9 in.lb Heater Outlet Screws 9 in.lb Heater Outlet Pipe Nut 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8827 Heater Core: Locations Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8828 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8829 Heater Core: Description and Operation The heater core transfers heat from the engine coolant to the incoming air. The heater core is located in the lower section of the heater module near the front of the dash. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8830 Heater Core: Service and Repair Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8831 (2 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Heater hoses from heater core. 4. Instrument Panel. 5. Heater core outlet. 6. Heater core cover. ^ There is a mounting screw located in a recess in the center of the cover 7. Heater core mounting clamps and beater core. Install or Connect 1. Heater core and heater core mounting clamps. Tighten ^ Screws to 1 Nm (9 lb in). 2. Heater core cover. Tighten ^ Screws to 1 Nm (9 lb in). 3. Heater core outlet. Tighten ^ Screws to 1 Nm (9 lb in). 4. Instrument Panel. 5. Heater hoses to heater core. 6. Fill cooling system and check for leaks. 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8832 Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission - Whine at 2800-3200 RPM Heater Hose: Customer Interest Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 99-01-38-003 > Sep > 99 > Engine/Transmission - Whine at 2800-3200 RPM Heater Hose: All Technical Service Bulletins Engine/Transmission - Whine at 2800-3200 RPM File In Section: 01 - HVAC Bulletin No.: 99-01-38-003 Date: September, 1999 TECHNICAL Subject: Engine/Transmission Whine at 2800-3200 RPM (Replace Heater Inlet Hose) Models: 1997-2000 Chevrolet Cavalier 1997-2000 Pontiac Sunfire with 2.2L Engine (VIN 4 - RPO LN2) Condition Some customers may comment on a whine from the engine/transmission at 2800-3200 RPM. Cause The production released heater inlet hose has an internal coolant flow restrictor. The flow of the coolant through the restrictor may induce a whine/whistle. In some cases the flow restrictor may migrate and come in contact with the heater core inlet tube. If the restrictor comes in contact with the heater core inlet pipe the whine may become audible within the passenger compartment of the vehicle. Correction Replace the heater inlet hose (P/N 22615693). Use the procedure found in the HVAC section of the Service Manual. The new part has a stainless steel clamp over the hose under the insulator where the flow restrictor is positioned. If the clamp is missing on the hose, do not use. All parts currently in GMSPO stock are of the new style. Parts Information Part Number Description 22615693 Hose, Heater Inlet Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time D2774 Hose, Heater Rear Inlet 0.9 hr (With Air Conditioning) - Replace Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8846 Heater Hose: Specifications Heater Hose and Pipe Torque Specifications Heater Hose and Pipe Torque Specifications Heater Outlet Screws 9 in.lb Heater Outlet Pipe Nut 18 ft.lb Heater Pipe Assembly to Engine Bolt and Nut 18 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8847 Heater Hose: Locations Heater Pipes The heater hoses are attached to the heater core at the front of dash and to the inlet and outlet pipes at the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8848 Heater Hose: Description and Operation The heater hoses and pipes carry engine coolant from the engine to the heater core. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Preliminary Instructions Heater Hose: Service and Repair Preliminary Instructions Heater Hoses Heater Pipes Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Make sure conduit and heat sleeving are in the same location as the original when replacing a hose. when servicing a heater hose with a quick connect assembly, REPLACEMENT OF THE RETAINER IS RECOMMENDED. Refer to Quick Connect Retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 8851 Heater Hose: Service and Repair Heater Hoses Heater Hoses Remove or Disconnect 1. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater hoses from heater pipes. 3. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Heater hoses to heater pipes. 3. Drain engine coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Preliminary Instructions > Page 8852 Heater Hose: Service and Repair Heater Pipe Assembly Heater Pipes Remove or Disconnect 1. Drain coolant. Refer to Draining and Refilling in Engine Cooling. 2. Heater core to pipe hoses from beater pipe assembly. 3. Heater pipe hose at coolant outlet on engine. 4. Heater pipe hose at coolant inlet on engine. 5. Bolt and nuts retaining pipe to engine. 6. Heater pipe assembly. Install or Connect 1. Heater pipe assembly. 2. Bolt and nuts retaining pipe to engine. Tighten ^ Bolt and nut to 25 N.m (18 lb ft). 3. Heater pipe hose to coolant inlet on engine. 4. Heater pipe hose to coolant outlet on engine. 5. Heater core to pipe hoses to heater pipe assembly. 6. Refill coolant. Refer to Draining and Refilling in Engine Cooling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Compressor Pressure Relief Valve HVAC Air Flow - Typical Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Compressor Pressure Relief Valve > Page 8857 Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Compressor Pressure Relief Valve High Pressure Safety Valve HVAC: Description and Operation Compressor Pressure Relief Valve V-5 Compressor The compressor is equipped with a pressure relief valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure. To prevent system damage, the valve is designed to open automatically when high side pressure exceeds a specified amount. Conditions that might cause this valve to open (defective A/C pressure sensor, inoperative electric cooling fan, etc.) should be corrected, and the refrigerant oil and refrigerant should be replaced as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Compressor Pressure Relief Valve > Page 8860 High Pressure Safety Valve HVAC: Description and Operation Pressure Relief Valve V-5 Compressor The compressor is equipped with a pressure relief valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure. To prevent system damage, the valve is designed to open automatically when high side pressure exceeds a specified amount. Conditions that might cause this valve to open (defective A/C pressure sensor, inoperative electric cooling fan, etc.) should be corrected, and the refrigerant oil and refrigerant should be replaced as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 8861 High Pressure Safety Valve HVAC: Service and Repair V5 Compressor Rear Head Details Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. remove old pressure relief valve. Install or Connect 1. Clean valve seal area on rear head. 2. Lubricate O-ring of new pressure relief valve and O-ring assembly with new 525 viscosity refrigerant oil. Install new valve and torque in place, 9.0 N.m (6.1 lbs. ft.). 3. Evacuate and recharge the system. 4. Leak test systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: Customer Interest A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 8870 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: All Technical Service Bulletins A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 8876 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Positive: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 8887 Hose/Line HVAC: Specifications A/C Accumulator Inlet Fitting 18 ft.lb A/C Accumulator Outlet Fitting 18 ft.lb A/C Accumulator Tube to Evaporator 18 ft.lb A/C Compressor and Condenser Hose Bolt to Rear of Compressor 24 ft.lb A/C Condenser Inlet From Evaporator Fitting Nut 12 ft.lb A/C Condenser Outlet Fitting Nut 12 ft.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube > Page 8890 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Locations > A/C Accumulator Tube > Page 8891 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) Hose/Line HVAC: Service and Repair Accumulator Tube (Evaporator to Accumulator) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Tube at accumulator and discard O-ring seal. 3. Raise vehicle. Refer to Lifting in General Information. 4. TUBE at evaporator and discard O-ring seals. 5. Lower vehicle, remove tube. Install or Connect 1. Set tube in place. Raise vehicle. 2. TUBE at evaporator using new O-ring seals. Tighten ^ Fitting to 24 N.m (18 lb ft). 3. Lower vehicle. 4. Tube at accumulator using a new O-ring seal. Tighten ^ Fitting to 24 N.m (18 lb ft). 5. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 8894 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Switch connection on discharge line. 3. Cruise control module (if equipped). 4. Suction line (accumulator to compressor) at accumulator. 5. Upper closeout panel. 6. Connection at the condenser. 7. Raise vehicle. 8. Block fitting at the rear head of the compressor. 9. Compressor/condenser hose assembly. Important ^ Remove and discard all used O-ring seals and sealing washers. Install or Connect 1. Compressor/condenser hose assembly. 2. Block fitting to reai head of compressor using new sealing washers. Refer to Sealing Washer Installation Procedures. Tighten ^ Bolt to 33 N.m (24 lb ft). 3. Lower vehicle. 4. Suction line at the accumulator using a new O-ring seal. Tighten ^ Nut to 24 N.m (18 lb ft). 5. Connection at the condenser using new O-ring seal. Tighten ^ Nut to 24 N.m (18 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 8895 6. Switch connection on discharge line. 7. Cruise control module. 8. Upper closeout panel. 9. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 10. Check system operation and leak test. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Accumulator Tube (Evaporator to Accumulator) > Page 8896 Hose/Line HVAC: Service and Repair Evaporator Tube (Evaporator to Condenser) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Upper closeout panel. 3. Connection from the condenser and discard the O-ring seal. 4. Tube from retaining clip on the body side rail. 5. Raise vehicle. Refer to Lifting in General Information. 6. Tube from the evaporator and discard the O-ring seals. 7. Lower the vehicle and remove the evaporator tube. Install or Connect 1. Set evaporator tube in place. 2. Raise vehicle. 3. Tube to evaporator using new O-ring seals. Tighten ^ Fitting to 24 N.m (18 lb ft). 4. Lower vehicle. 5. Tube to retaining clip on the body side rail. 6. Connection at condenser using new O-ring seals. Tighten ^ Nut to 16 N.m (12 lb ft). 7. Upper closeout panel. 8. Evacuate and charge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications Housing Assembly HVAC: Specifications Heater and Vent Module Torque Specifications Heater and Vent Module Torque Specifications Heater and Vent Module Screws 27 in.lb Heater and Vent Module Stud 27 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Heater Module Heater Module To Dash Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Heater Module > Page 8902 HVAC Module To Dash Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 8903 Housing Assembly HVAC: Description and Operation The recirculation feature is driven by the air inlet valve. The valve is linked to a vacuum actuator that is controlled by the mode knob of the control assembly. The valve allows fresh (outside) air to enter the passenger compartment when open. The valve will force the passenger compartment air to be recirculated when the valve is closed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module Housing Assembly HVAC: Service and Repair Heater Module Heater Module To Dash Panel Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Heater hoses at the heater core. 4. Module attaching bolts. 5. Instrument panel and instrument panel tie bar. 6. Floor air outlet. 7. Wiring harness from module. 8. Electrical connections at blower motor and blower resistor. 9. Module from the vehicle. Install or Connect 1. Module in the vehicle. Tighten ^ Bolts to 3 N.m (27 lb in). 2. Electrical connections at blower motor and blower resistor. 3. Wiring harness to module. 4. Floor air outlet. 5. Instrument panel tie bar and instrument panel. 6. Module attaching bolts (upper first then lower). Tighten ^ Bolts to 3 N.m (27 lb in). 7. Heater hoses at heater core. 8. Fill cooling system. 9. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module > Page 8906 Housing Assembly HVAC: Service and Repair Air Inlet (Recirculation) Valve HVAC Module - Top And Left View Remove or Disconnect 1. HVAC module from vehicle, 2. Recirculation valve vacuum actuator from module. 3. Recirculation valve inlet housing from module. 4. Recirculation valve from inlet housing. Install or Connect 1. Recirculation valve to inlet housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module > Page 8907 2. Recirculation valve inlet housing to module. Tighten ^ Screws to 1 N.m (9 lb in). 3. Recirculation valve vacuum actuator to module. 4. HVAC module to vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module > Page 8908 Housing Assembly HVAC: Service and Repair HVAC Module HVAC Module To Dash Panel Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station. Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Recover refrigerant. 4. Evaporator lines from evaporator. 5. Heater hoses at the heater core. 6. Module attaching bolts. 7. Instrument panel and Instrument panel tie bar. 8. Floor air outlet. 9. Wiring harness from module. 10. Electrical connections at blower motor and blower resistors. 11. Module from the vehicle. Install or Connect 1. Module in the vehicle. 2. Electrical connections at blower motor and blower resistor. 3. Wiring harness to module. 4. Floor air outlet. 5. Instrument panel tie bar and Instrument panel. 6. Module attaching bolts (upper first then lower). Tighten ^ Bolts to 3 N.m (37 lb in). 7. Heater hoses at heater core and evaporator lines at evaporator Tighten ^ Fittings to 24 N.m (18 lb ft). 8. Evacuate and charge A/C system. 9. Fill cooling system. 10. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 8913 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 8914 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 8915 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 8916 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Charge Capacity 1.5 lb (US) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8919 Refrigerant: Fluid Type Specifications Refrigerant Type R-134a GM P/N 12345922 Or Equivalent Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8920 Refrigerant: Service Precautions Refrigerant drums have a heavy metal cap. The cap protects the valve and safety plug from damage.For this reason, always replace the cap after each use. Whenever a container of refrigerant must be carried in a vehicle, do not carry it in the passenger compartment. See the manufacturers guidelines for storage, transportation and the maximum temperature to which the container can be exposed. When filling a small refrigerant drum from a large one, never fill the smaller drum completely. Always leave space for the liquid to expand. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8921 Refrigerant: Description and Operation The air conditioning system contains Refrigerant-134a, which requires special handling to avoid personal injury. Refer to Handling Refrigerant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Refrigerant Oil Capacity Polyalkaline Glycol (PAG) Synthetic Refrigerant Lubricant 9 oz (US) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8928 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Polyalkylene Glycol (PAG) Synthetic Refrigerant Lubricant Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Sensor Torque Specification A/C Pressure Sensor Torque Specification A/C Pressure Sensor Fitting 44 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8932 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8933 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8934 Refrigerant Pressure Sensor / Switch: Description and Operation An electronic A/C pressure sensor is mounted in the line (between the compressor and the condenser). Its output to the PCM is variable and is dependent upon pressure inside the line. A higher pressure results in a higher voltage output. The PCM constantly monitors A/C system pressure to: 1. Disengage the A/C clutch if the pressures are too high. 2. Disengage the A/C clutch if pressures are too low. 3. Boost idle air control to compensate for A/C load at idle. 4. Control cooling fan operation. The pressure sensor is not repairable, if it fails, it must be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cutout functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. Tighten ^ Sensor to 5 Nm (44 lb in). 3. Electrical connection at the sensor. 4. Negative battery cable. Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8937 Refrigerant Pressure Sensor / Switch: Service and Repair Control Switches Conventional Mounted Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8938 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Direct Mounted Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8939 Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8940 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C COMPRESSOR CONTROL RELAY Fuse Block Details The A/C Compressor Control Relay is located in the Engine Compartment Fuse/Relay Center. The Engine Compartment Fuse/Relay Center is located in the left front of the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8945 Compressor Clutch Relay: Description and Operation The A/C compressor control relay is designed to disengage the A/C compressor clutch momentarily during start-up on a warm engine. The relay is PCM controlled. Voltage is supplied from the A/C power feed circuit and the PCM completes the ground to close a set of normally opened points. This turns the compressor clutch ON. The PCM opens the ground circuit when an engine run signal is sensed with coolant temperature at a specified amount. On a warm engine start-up, a time delay of about 3 seconds allows the engine speed to stabilize before the compressor engages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation The blower speed is controlled by a knob which actuates a switch. The blower circuit is open in the OFF mode. In all other modes the blower has 4 speeds to control the amount of air that flows through the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. Instrument Panel trim plate. Refer to Trim Plate in instrument Panel, Gauges and Console. 3. Control assembly screws and pull control assembly away from the instrument Panel. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. Tighten ^ Screws fully driven, seated and not stripped. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. Tighten ^ Screws to 2 N.m (18 lb in). 5. Instrument Panel trim plate. 6. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Sensor Torque Specification A/C Pressure Sensor Torque Specification A/C Pressure Sensor Fitting 44 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8956 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8957 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8958 Refrigerant Pressure Sensor / Switch: Description and Operation An electronic A/C pressure sensor is mounted in the line (between the compressor and the condenser). Its output to the PCM is variable and is dependent upon pressure inside the line. A higher pressure results in a higher voltage output. The PCM constantly monitors A/C system pressure to: 1. Disengage the A/C clutch if the pressures are too high. 2. Disengage the A/C clutch if pressures are too low. 3. Boost idle air control to compensate for A/C load at idle. 4. Control cooling fan operation. The pressure sensor is not repairable, if it fails, it must be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cutout functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. Tighten ^ Sensor to 5 Nm (44 lb in). 3. Electrical connection at the sensor. 4. Negative battery cable. Tighten ^ Bolt to 16 Nm (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8961 Refrigerant Pressure Sensor / Switch: Service and Repair Control Switches Conventional Mounted Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8962 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Direct Mounted Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8963 Compressor Components - Disassembled View Remove or Disconnect 1. Recover refrigerant using J 39500-GM 2. Disconnect the electrical connector from the switch in the rear head of the compressor. 3. Remove the switch retaining ring, using J 5403 internal snap ring pliers. 4. Remove switch from compressor. 5. Remove old O-ring seal from switch cavity using J 955301 O-ring removal tool or equivalent. NOTICE: If existing switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included. Install or Connect Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Sensor > Page 8964 1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity. 2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch "bottoms" in cavity. 3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove. 4. Evacuate and recharge the system. 5. Leak test referring to "Compressor Leak Testing". Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The Schrader valve is located under the A/C pressure sensor in the compresssor discharge hose. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8968 Service Port HVAC: Service and Repair Tools Required: J 241 82-2A Valve Core Remover/Installer J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. 2. Harness from pressure sensor. 3. Pressure sensor from fitting. 4. Schrader valve from fitting. Install or Connect 1. New valve to fitting. Tighten ^ Valve, Hand Tight. 2. Pressure sensor to fitting. Tighten ^ Sensor to 5 N.m (44 lb in). 3. Harness to pressure sensor. 4. Recharge A/C system. Refer to Refrigerant Recovery and Recycling, Discharging, Adding Oil, Evacuating and Charging the Refrigerant System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Vacuum Harness Vacuum Harness HVAC: Locations Vacuum Harness Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Vacuum Harness > Page 8973 (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Vacuum Harness > Page 8974 Vacuum Harness HVAC: Locations Vacuum Hose Harness The vacuum hose harness is located under the instrument panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Page 8975 Vacuum Harness HVAC: Service and Repair Vacuum Harness Color Code Remove or Disconnect 1. Negative battery cable. 2. Instrument panel pad. Refer to Instrument Panel Trim Pad in Instrument Panel, Gauges and Console. 3. Air distribution duct. 4. Vacuum lines from the vacuum actuators and vacuum tank. 5. Harness from control Install or Connect 1. Harness to control assembly. 2. Vacuum lines to the vacuum actuators. 3. Air distribution duct. 4. Instrument Panel Trim Pad. 5. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications Vacuum Reservoir HVAC: Specifications Vacuum Reservoir Torque Specifications Vacuum Reservoir Torque Specifications Vacuum Tank Screw 9 in.lb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 8979 Vacuum Reservoir HVAC: Locations The vacuum tank is located on top of the HVAC module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 8980 Vacuum Reservoir HVAC: Service and Repair Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 8981 (2 Of 2) During heavy acceleration the vacuum supply from the intake manifold drops. Under load conditions a check valve in the vacuum tank maintains vacuum so that it will be available for continuous use by the vacuum operated actuators. Remove or Disconnect 1. Negative battery cable. 2. Instrument panel Trim Pad. Refer to Instrument Panel Pad in Instrument Panel, Gauges and Console. 3. Air distribution ducts. 4. Vacuum line from tank. 5. Vacuum tank from module. Install or Connect 1. Vacuum tank. Tighten ^ Screw to 1 N.m (9 lb in). 2. Vacuum line to tank. 3. Air distribution ducts. 4. Instrument panel pad. 5. Negative battery cable. Tighten ^ Bolt to 16 N.m (12 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8988 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8989 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8990 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8991 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Instrument Panel Inflator Module Instrument Panel Inflator Module Mounting Fasteners 3.5 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Air Bag: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 8997 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 8998 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 8999 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Inflator Module Driver Inflator Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Inflator Module > Page 9002 Passenger Inflator Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 9003 Air Bag: Service Precautions NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 9004 Air Bag: Description and Operation The inflator modules consist of an inflatable bag and an inflator. An inflator consists of a canister of gas-generating material and an initiating device. The initiator is part of the deployment loop. When the vehicle is in a frontal crash of sufficient force, the inflatable restraint Sensing and Diagnostic Module (SDM) causes current to flow through the deployment loops. Current passing through the initiator ignites the material in the inflator module. The gas produced from this reaction rapidly inflates the air bag. There is a shorting bar on the inflatable restraint steering wheel module side of the upper steering column connector that connects the inflatable restraint steering wheel module coil to the inflatable restraint steering wheel module. The shorting bar shorts across the inflatable restraint steering wheel module circuits during the disconnection of the upper steering column connector. The shorting of the inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint steering wheel module, the steering column or other SIR system components. There is a shorting bar on the inflatable restraint IP module connector that connects to the SIR wiring harness. The shorting bar shorts across the inflatable restraint IP module circuits during the disconnection of the inflatable restraint IP module connector The shorting of the inflatable restraint IP module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint IP module, the instrument panel or other SIR system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures Air Bag: Service and Repair Deployment Procedures Inside of Vehicle (Vehicle Scrapping Procedure) Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during a theft. ^ The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module yellow 2-way connector. 6. Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 4.6 M (15 ft) deployment wires from a 0.8mm sq. (18 gage) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9007 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connection is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2-way connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9008 17. Route the deployment harness out of the vehicle's driver side. Figure 27 18. Disconnect the inflatable restraint IP module yellow 2-way harness connector. 19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1 M (20 ft) deployment wires from a 0.8mm sq. (18 gage) or thicker multi-strand wire. These wires will be used to fabricate the passenger deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together one end from each of the wires in order to short the wires. 24. Twist together one connector wire lead to one deployment wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9009 25. Bend flat the twisted connection. 26. Secure and insulate the connection using electrical tape. 27. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way connector. 29. Route the deployment harness out of the passenger side of the vehicle. 30. Clear the inside and outside of the vehicle of any people or loose and flammable objects. 31. Stretch the driver harness to full length. 32. Stretch the passenger harness to full length. 33. Completely cover the windshield and front door window openings with a drop cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9010 34. Place a power source, 12V minimum 12A minimum (i.e., a vehicle battery) near the shorted end of the harness. 35. Separate the two ends of the driver deployment harness wires. 36. Connect the driver deployment harness wires to the power source in order to deploy the inflatable restraint steering wheel module. 37. Disconnect the driver deployment harness wires from the power source. 38. Separate the two ends of the passenger deployment harness wires. 39. Connect the passenger deployment harness wires to the power source in order to deploy the inflatable restraint IP module. 40. Disconnect the passenger deployment harness wires from the power source. 41. Twist together one end of each wire on the driver deployment harness in order to short the wires. 42. Twist together one end of each wire on the passenger deployment harness in order to short the wires. 43. Remove the drop cloth from the vehicle. 44. Disconnect both harnesses from the vehicle. 45. Discard the harnesses. 46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 47. If one or both of the modules did not deploy, perform the following steps: 47.1. Remove the undeployed module(s) from the vehicle. Refer to Inflatable Restraint Steering Wheel Module and Inflatable Restraint IP Module. 47.2. Temporarily store the module(s). 47.3. Call the Technical Assistance Group for further assistance. Inflatable Restraint Steering Wheel Module Tools Required ^ J 38828 SIR Deployment Harness ^ An appropriate pigtail adapter CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste The undeployed inflator module contains substances that could cause severe illness or personal injury if Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9011 the sealed container is damaged during disposal Use the following deployment procedures to safely dispose of an undeployed inflator module Failure to dispose of an inflator module as instructed may be a violation of federal state, province, or local laws. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Deploy the inflatable restraint steering wheel inflator module outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: ^ Using the SIR diagnostics, you determine that the inflator module does not function properly. ^ The inflator module is scratched or ripped on the coven ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. 1. Turn the ignition switch to the OFF position. 2. Remove the ignition key. 3. Put on safety glasses. 4. Inspect the J 38626 and the appropriate pigtail adapter for damage. Replace as needed. 5. Short the two SIR deployment harness (1) leads together using one banana plug seated into the other. 6. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 7. Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module in Steering Column Steering Wheels. 8. Remove the horn lead from the back of the module, if equipped. 9. Remove the redundant steering wheel control leads from the back of the module, if equipped. 10. Remove all horn/steering wheel control buttons from the module, if equipped. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 11. Place the module with the vinyl trim cover facing up and away from the surface on a work bench. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9012 12. Clear a space on the ground about 1.85 M (6 ft) in diameter for deployment of the module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 13. Make sure no loose or flammable objects are in the area. 14. Place the module in the space with the vinyl trim cover facing up. 15. Extend the SIR deployment harness and adapter to full length from the module. 16. Place a 12V minimum/2A minimum power source (i.e., vehicle battery) near the shorted end of the harness. 17. Connect the module (1) to the adapter (2) on the SIR deployment harness (3). 18. Firmly seat the adapter into the module connector. 19. Clear the area of people. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9013 20. Separate the two banana plugs on the SIR deployment harness. IMPORTANT: The rapid gas expansion involved with deploying an air bag is very loud. Notify all the people in the immediate area that you intend to deploy the inflator module. IMPORTANT: When the air bag deploys, the inflator module may jump about 30 cm (1 ft) vertically. This is a normal reaction of the inflator module to the force of the rapid gas expansion inside the air bag. 21. Connect the SIR deployment harness wires to the power source. 22. Disconnect the SIR deployment harness from the power source after the air bag deploys. 23. Seat one banana plug into the other in order to short the deployment harness leads. 24. If the air bag did not deploy. disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the inflator module are very hot. Do not place the deployed inflator module near any flammable objects. Wait for about ten minutes before touching any metal surface of the inflator module. Disregarding these precautions may cause fire or personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9014 25. Put on a pair of shop gloves. 26. Disconnect the pigtail adapter from the inflator module as soon as possible. 27. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed. 28. Dispose of the deployed module through normal refuse channels. 29. Wash hands with a mild soap. Inflatable Restraint IP Module Dealers should refer to the latest General Motors Service Bulletins for live (undeployed) inflatable restraint IP module scrapping and disposal procedures. All others should contact a local General Motors dealer for these procedures. Dispose of deployed IP modules through normal refuse channels. Preliminary The inflator module can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9015 Air Bag: Service and Repair Handling/Shipping/Scrapping Handling A Deployed Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Handling A Live (Undeployed) Inflator Module CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. Live (Undeployed) Inflator Module Take special care when handling or storing a live (undeployed) inflator module. An air bag deployment produces rapid gas generation. This may cause the inflator module, or an object in front of the inflator module, to jettison through the air in the, event of an unlikely deployment. Scrapping Procedures During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. The following information covers the proper procedures for the disposing of a live inflator module. Deploy the inflator module before disposal. Do not dispose of the module through normal disposal channels. CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or local laws. Do not deploy an air bag in the following situations: ^ After replacement of an inflator module under warranty. The module may need to be returned undeployed to the Delphi Interior & Lighting Group. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If the vehicle is the subject of a Product Liability report related to the SIR system and is subject to a Preliminary Investigation (GM-1241). Do not alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. Shipping Procedures For Live (Undeployed) Inflator Modules Refer to the latest service bulletins for proper SIR inflator module shipping procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9016 Air Bag: Service and Repair Passenger's Inflator Module Removal 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the IP trim pad. Refer to IP Trim Pad in Instrument Panel, Gauges and Console. 3. Remove the Connector Position Assurance (CPA) from the inflatable restraint IP module yellow 2-way pigtail connector. 4. Disconnect the inflatable restraint IP module yellow 2-way pigtail connector from the SIR wiring harness jumper. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9017 5. Remove the inflatable restraint IP module mounting fasteners (2). 6. Remove the inflatable restraint IP module (1) from the instrument panel (3). Installation 1. Install the inflatable restraint IP module (1) to the instrument panel (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the inflatable restraint IP module mounting fasteners (2). Tighten Tighten fasteners to 3.5 N.m (31 lb. in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9018 3. Connect the inflatable restraint IP module yellow 2-way pigtail connector to the SIR wiring harness jumper. 4. Install the Connector Position Assurance (CPA) to the inflatable restraint IP module yellow 2-way pigtail connector. 5. Install the IP trim pad. 6. Enable the SIR system. Important Preliminary Precautions CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module ^ Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployment Procedures > Page 9019 Air Bag: Service and Repair Steering Wheel Air Bag Module Replacement REMOVE OR DISCONNECT 1. Disable the Supplemental Inflatable Restraint (SIR) system. 2. Two screws from the back of the steering wheel using a Hex Head driver (or equivalent). 3. Connector position assurance (CPA) and electrical connection from rear of inflator module. 4. Inflator module. INSTALL OR CONNECT 1. CPA to rear of inflator module. 2. Inflator module to steering wheel and four screws through back of steering wheel. ^ Tighten screws to 10 Nm (89 inch lbs.). 3. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Sensing and Diagnostic Module Sensing and Diagnostic Module Mounting Fasteners 14 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 9025 Air Bag Control Module: Locations Sensing and Diagnostic Module (SDM) Component Location Views At the right passenger compartment, under the right seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9026 Air Bag Control Module: Diagrams Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9027 Air Bag Control Module: Description and Operation The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a Diagnostic Trouble Code (DTC). ^ Malfunction Diagnosis - The SDM displays SIR Diagnostic Trouble Codes and system status information through the use of a scan tool. ^ Driver Notification - The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. If this connector is removed from the SDM, the UART data link is broken and the Instrument Panel Cluster (IPC) will turn the AIR BAG warning lamp ON steady whenever the ignition switch is in the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury, Before attempting these procedures, the SIR system must be disabled. Refer to Disabling SIR System. With the ignition OFF inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9030 Air Bag Control Module: Service and Repair Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. Refer to Driver Or Passenger Front Seat in Seats and Carpet. 3. Remove the passenger front carpet retainer, then roll back the carpet. Refer to Floor Carpet Retainer in Seats and Carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint Sensing and Diagnostic Module (SDM) harness connector. Description 5. Disconnect the SDM harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9031 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). IMPORTANT: If the SDM mounting holes or fasteners are damaged to the extent that the module can no longer be properly mounted use the following repair. Torque the replacement fastener with a hand tool in order to prevent stripping the replacement fastener. 1. Remove the stripped fastener and discard it. 2. Drill and tap the weld nut for use with a 7.00 x 1.0 mm bolt. NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 3. Install the SDM with new fastener GM P/N 25601790. 4. Tighten Tighten fastener to 14 N.m (124 lb. in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9032 Air Bag Control Module: Service and Repair Installation Procedure 1. Install the SDM (1) to the floor pan (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the SDM mounting fasteners (2). Tighten Tighten fasteners to 14 N.m (124 lb. in). Description 3. Install the SDM harness connector to the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9033 4. Install the Connector Position Assurance (CPA) to the SDM harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations > Driver Safing Connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations > Driver Safing Connector > Page 9038 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Clockspring Assembly / Spiral Cable: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 9042 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 9043 Clockspring Assembly / Spiral Cable: Description and Operation The inflatable restraint steering wheel module coil consists of two or more current-carrying coils. The inflatable restraint steering wheel module coil attaches to the steering column. Two of the current-carrying coils allow rotation of the steering wheel while maintaining continuous contact of the driver deployment loop to the inflatable restraint steering wheel module. There is a shorting bar on the yellow 2-way connector near the base of the steering column that connects the inflatable restraint steering wheel module coil to the SIR wiring harness. The shorting bar shorts the circuits to the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module during the disconnection of the yellow 2-way connector. The shorting of the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the steering column or other SIR system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil > Page 9046 Clockspring Assembly / Spiral Cable: Service and Repair SIR Coil Assembly NOTE: Refer to Steering Column Unit Repair for additional procedures. REMOVE OR DISCONNECT Important: Disable the Supplemental Inflatable Restraint (SIR) system. 1. Steering wheel assembly. 2. Coil assembly retaining clip. 3. Coil assembly off shaft end letting coil hang freely. 4. Wave washer. 5. Spacer shaft lock (standard column only). 6. Shaft lock retaining ring using J 23563-C to compress lock. 7. Pry off retaining ring. 8. Shaft lock. 9. Turn signal canceling cam assembly. 10. Upper bearing spring. 11. Turn signal to right turn position (up). 12. Multifunction lever. 13. Hazard knob assembly. 14. Screw and signal switch arm. ^ Let switch arm hang freely (tilt option equipped with cruise only). 15. Screws, turn signal switch. ^ Let turn signal switch hang freely. 16. Remove coil assembly connector shroud. 17. Steering column support bracket bolts. 18. Upper steering column bolts. 19. Wiring protector. 20. Connect a length of mechanic's wire to coil assembly terminal connector to aid in reassembly. 21. Gently pull wire harness through steering column housing shroud, steering column housing and lock assembly cover. 22. Remove mechanic's wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil > Page 9047 INSTALL OR CONNECT NOTICE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 1. Connect mechanic's wire to centering coil assembly connector. 2. Gently pull connector through steering column housing shroud, steering column housing and lock assembly. 3. Remove mechanic's wire. 4. Install wiring protector. 5. Install connector shroud. 6. Connector centering coil assembly terminal connector. 7. Steering column lower support bracket to steering column. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 8. Steering column upper support bolts. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 9. Turn signal switch assembly. ^ Tighten bolts to 3.4 Nm (30 inch lbs.). 10. Signal switch arm (tilt steering column only). ^ Tighten bolts to 2.3 Nm (20 inch lbs.). 11. Hazard knob assembly. 12. Multifunction lever. 13. Turn signal canceling cam assembly. ^ Lubricate with grease, synthetic (service kit). 14. Shaft lock. ^ Inspect shaft lock retaining ring for damage or deformation. Replace with new retaining ring. 15. Shaft lock retaining ring. Line up to block tooth on shaft using J 23653-C to compress shaft lock. ^ Shaft lock retaining ring must be firmly seated in groove on shaft. 16. Spacer shaft lock (standard column only). 17. Ensure coil assembly is centered. Important: Assemble pre-centered coil assembly to steering column. Remove centering tab and dispose. Important: Coil assembly will become un-centered if: a. Steering column is separated form steering gear and is allowed to rotate. b. Centering spring is pushed down, letting hub rotate while coil is removed from steering column. In the event this occurs, refer to "Centering Coil Assembly." 18. Coil assembly using horn tower on canceling cam assembly inner ring and projections on outer ring for alignment. 19. Coil assembly retaining ring. ^ Ring must be firmly in groove on shaft. Important: Gently pull lower coil assembly wire to remove any wire kinks that may be inside column assembly. It is absolutely critical that you make sure there are no kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Then turning of the steering wheel may cut or damage wire. 20. Steering wheel assembly. 21. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil > Page 9048 Clockspring Assembly / Spiral Cable: Service and Repair Steering Column Referral Refer to SIR coil assembly in Supplemental Inflatable Restraint (SIR) Standard Steering Column Floor Shift Unit Repair of Supplemental Inflatable Restraint (SIR) tilt steering wheel module coil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Front End Descriminating Sensor Front End Descriminating Sensor Mounting Fasteners 10 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor > Page 9054 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 9055 Auxiliary Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 9056 Impact Sensor: Description and Operation The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint Sensing and Diagnostic Module (SDM). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor Important Preliminary Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the Connector Position Assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9059 4. Remove the inflatable restraint front end discriminating sensor mounting fasteners (2). 5. Remove the inflatable restraint front end discriminating sensor (1) from the hood latch support bracket (3). Installation Procedure 1. Install the inflatable restraint front end discriminating sensor (1) to the hood latch support bracket (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Tighten Tighten fasteners to 10 N.m (89 lb. in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9060 4. Install the Connector Position Assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9061 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Malfunction Lamp / Indicator: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: Customer Interest SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Malfunction Lamp / Indicator: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: All Technical Service Bulletins SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Page 9079 Malfunction Lamp / Indicator: Description and Operation The ignition switch applies ignition voltage to the AIR BAG warning lamp. The AIR BAG warning lamp receives power whenever the ignition switch is at the OFF/UNLOCK, RUN or START positions. The inflatable restraint Sensing and Diagnostic Module (SDM) controls the lamp via serial data communication on the UART data line CKT 800. If the AIR BAG warning lamp fails to come ON at all, refer to Telltales in Instrument Panel Cluster (IPC) Microprocessor. The SIR system uses the AIR BAG warning lamp to do the following: ^ Verify lamp and SDM operation by flashing the lamp seven times when the ignition switch is first turned to the RUN position. ^ Warn the vehicle driver of SIR electrical system malfunctions which could potentially affect the operation of the SIR system. These malfunctions could result in either of the following conditions: - Non-deployment in the case of a frontal crash - Deployment for conditions less severe than intended The AIR BAG warning lamp is the key to driver notification of SIR system malfunctions. Refer to SIR Diagnostic System Check for proper lamp operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Page 9080 Malfunction Lamp / Indicator: Service and Repair The AIR BAG warning lamp is a replaceable bulb in the Instrument Cluster. Refer to Instrument Panel, Gauges and Warning Indicators. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation The knee bolsters absorb energy and control the forward movement of the vehicle's front seat occupants during a frontal crash, by limiting leg movement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Sensing and Diagnostic Module Sensing and Diagnostic Module Mounting Fasteners 14 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 9094 Air Bag Control Module: Locations Sensing and Diagnostic Module (SDM) Component Location Views At the right passenger compartment, under the right seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9095 Air Bag Control Module: Diagrams Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9096 Air Bag Control Module: Description and Operation The inflatable restraint Sensing and Diagnostic Module (SDM) performs the following functions in the SIR system: ^ Energy Reserve - The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection - The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment - During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording - The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection - The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a Diagnostic Trouble Code (DTC). ^ Malfunction Diagnosis - The SDM displays SIR Diagnostic Trouble Codes and system status information through the use of a scan tool. ^ Driver Notification - The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. If this connector is removed from the SDM, the UART data link is broken and the Instrument Panel Cluster (IPC) will turn the AIR BAG warning lamp ON steady whenever the ignition switch is in the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury, Before attempting these procedures, the SIR system must be disabled. Refer to Disabling SIR System. With the ignition OFF inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9099 Air Bag Control Module: Service and Repair Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the passenger front seat. Refer to Driver Or Passenger Front Seat in Seats and Carpet. 3. Remove the passenger front carpet retainer, then roll back the carpet. Refer to Floor Carpet Retainer in Seats and Carpet. 4. Remove the Connector Position Assurance (CPA) from the inflatable restraint Sensing and Diagnostic Module (SDM) harness connector. Description 5. Disconnect the SDM harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9100 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). IMPORTANT: If the SDM mounting holes or fasteners are damaged to the extent that the module can no longer be properly mounted use the following repair. Torque the replacement fastener with a hand tool in order to prevent stripping the replacement fastener. 1. Remove the stripped fastener and discard it. 2. Drill and tap the weld nut for use with a 7.00 x 1.0 mm bolt. NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 3. Install the SDM with new fastener GM P/N 25601790. 4. Tighten Tighten fastener to 14 N.m (124 lb. in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9101 Air Bag Control Module: Service and Repair Installation Procedure 1. Install the SDM (1) to the floor pan (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the SDM mounting fasteners (2). Tighten Tighten fasteners to 14 N.m (124 lb. in). Description 3. Install the SDM harness connector to the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9102 4. Install the Connector Position Assurance (CPA) to the SDM harness connector. 5. Install the carpet and the passenger front carpet retainer. 6. Install the passenger front seat. 7. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9108 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9109 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9110 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9111 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 9117 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose Seat Belt: Customer Interest Seat Shoulder Belt (Front) - Plastic Cover Comes Loose File In Section: 09 - Restraints Bulletin No.: 99-09-40-001 Date: May, 1999 TECHNICAL Subject: Front Seat Shoulder Belt Plastic Cover at Pillar Will Not Stay Fastened (Replace Bolt) Models: 1995-99 Chevrolet Cavalier (Coupe Only) 1995-99 Pontiac Sunfire (Coupe Only) Condition Some customers may comment that the front seat shoulder belt plastic cover will not stay snapped in place. This cover hides the bolt that attaches to the pillar. Correction Replace the shoulder belt to the pillar attaching bolt with new bolt P/N 15674851, using the following service procedure. Inspect the plastic cover for cracks or damage and replace the cover if necessary. Also replace the shoulder belt bolt and inspect the cover on the opposite side of the vehicle. Service Procedure 1. Remove and inspect the plastic cover by pulling on the bottom of the cover (2). 2. Remove the shoulder belt to the pillar attaching bolt (1). 3. Install the new shoulder belt to the pillar attaching bolt (1) and tighten to 42 N.m (31 lb ft). 4. Install the plastic cover over the bolt head (2). 5. Repeat the procedure on the opposite side of the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose > Page 9126 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use: Labor Labor Operation Description Time Shoulder Belt to Pillar C9050 Attaching Bolts - Replace Both 0.2 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) Plastic Cover Comes Loose Seat Belt: All Technical Service Bulletins Seat Shoulder Belt (Front) - Plastic Cover Comes Loose File In Section: 09 - Restraints Bulletin No.: 99-09-40-001 Date: May, 1999 TECHNICAL Subject: Front Seat Shoulder Belt Plastic Cover at Pillar Will Not Stay Fastened (Replace Bolt) Models: 1995-99 Chevrolet Cavalier (Coupe Only) 1995-99 Pontiac Sunfire (Coupe Only) Condition Some customers may comment that the front seat shoulder belt plastic cover will not stay snapped in place. This cover hides the bolt that attaches to the pillar. Correction Replace the shoulder belt to the pillar attaching bolt with new bolt P/N 15674851, using the following service procedure. Inspect the plastic cover for cracks or damage and replace the cover if necessary. Also replace the shoulder belt bolt and inspect the cover on the opposite side of the vehicle. Service Procedure 1. Remove and inspect the plastic cover by pulling on the bottom of the cover (2). 2. Remove the shoulder belt to the pillar attaching bolt (1). 3. Install the new shoulder belt to the pillar attaching bolt (1) and tighten to 42 N.m (31 lb ft). 4. Install the plastic cover over the bolt head (2). 5. Repeat the procedure on the opposite side of the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) Plastic Cover Comes Loose > Page 9132 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use: Labor Labor Operation Description Time Shoulder Belt to Pillar C9050 Attaching Bolts - Replace Both 0.2 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Front Seat Belts Seat Belt: Specifications Front Seat Belts Front Seat Belts (Coupe) Front Seat Belts (Coupe) Retractor Side Belt Sleeve Bolt 42 Nm Shoulder Belt Pillar Guide Bolt 42 Nm Shoulder Belt Retractor Bolt 42 Nm Front Seat Belts (Sedan) Front Seat Belts (Sedan) Retractor Side Belt Sleeve Bolt 42 Nm Shoulder Belt Pillar Guide Bolt 28 Nm Shoulder Belt Retractor Bolt 42 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Front Seat Belts > Page 9135 Seat Belt: Specifications Rear Seat Belts Rear Seat Belts Center Belt Anchor Nuts 42 Nm Side Belt Retractor Bolt 42 Nm Side Belt Floor Anchor Bolt 42 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal Procedure Seat Belt: Service and Repair Removal Procedure Description 1. Remove the rear seat cushion. Refer to Seats and Carpet. 2. Remove the rear seat center belt nut. 3. Remove the rear seat center belt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal Procedure > Page 9138 Seat Belt: Service and Repair Installation Procedure Description 1. Install the rear seat center belt. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat center belt nut. Tighten Tighten the rear seat center belt nut to 42 N.m (31 lb. ft). 3. Install the rear seat cushion. Refer to Seats and Carpet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9147 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9153 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 9154 Seat Belt Buckle: Specifications Front Seat Belt Buckle Front Seat Belt Buckle Belt Bolt 47 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver Seat Buckle Side Belt Replacement Seat Belt Buckle: Service and Repair Driver Seat Buckle Side Belt Replacement Removal Procedure Description 1. Remove the driver seat assembly. Refer to Seats and Carpet. 2. Remove the driver seat buckle side belt bolt (1). 3. Remove the driver seat buckle side belt. Installation Procedure Description 1. Install the driver seat buckle side belt. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the driver seat buckle side belt bolt (1). Tighten Tighten the driver seat side belt bolt to 47 N.m (35 lb. ft). 3. Install the driver seat assembly. Refer to Seats and Carpet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver Seat Buckle Side Belt Replacement > Page 9157 Seat Belt Buckle: Service and Repair Passenger Seat Buckle Side Belt Replacement Removal Procedure Description 1. Position the passenger seat assembly forward in order to access the passenger seat buckle belt bolt. 2. Remove the front seat belt sleeve plug (2). 3. Remove the passenger seat buckle side belt bolt (3). 4. Remove the passenger seat buckle side belt. Installation Procedure Description 1. Install the passenger seat buckle side belt. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the passenger seat buckle side belt bolt (3). Tighten Tighten the passenger seat side belt bolt to 47 N.m (35 lb. ft). 3. Install the front seat belt sleeve plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations Seat Belt Buckle Switch: Component Locations At the left passenger compartment, under the left seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations > Page 9162 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 9163 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Seat Belts - Latch Slides To Seat Belt Anchor Sleeve Seat Belt Latch: Technical Service Bulletins Seat Belts - Latch Slides To Seat Belt Anchor Sleeve File In Section: 10 Body Bulletin No.: 73-16-16A Date: April, 1998 Subject: Seat Belt Latch Slides to Seat Belt Anchor Sleeve (Install Seat Belt Webbing Stop Button) Models: 1996-98 Buick Skylark 1995-98 Chevrolet Cavalier 1997-98 Chevrolet Malibu 1996-98 Oldsmobile Achieva 1999 Oldsmobile Alero 1997-98 Oldsmobile Cutlass 1995-98 Pontiac Sunfire 1996-99 Pontiac Grand Am This bulletin is being revised to update applicable models. Please discard Corporate Bulletin Number 73-16-16 (Section 10 - Body) Condition Some owners may comment that the seat belt latch slides to the seat belt anchor sleeve. Cause The web stop comfort convenience button may have separated from the webbing. Correction Refer to Figure 1. 1. Install seat belt webbing stop button in existing hole. 2. If unable to locate existing hole, remove bolt cap cover at rocker/floor pan mounting and measure from the center of bolt head; place the seat belt webbing stop button in the center of webbing using the following dimensions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Seat Belts - Latch Slides To Seat Belt Anchor Sleeve > Page 9172 ^ Alero and Grand Am (1999), Cavalier, Cutlass and Malibu (Coupe and Sedan) - 460 mm (18 inches). ^ Grand Am (1996-98), Skylark and Achieva (Coupe and Sedan) - 555 mm (22 inches). a. Make sure latch is above the seat belt webbing stop button. b. Use caution when snapping button halves together. c. Remove the sharp point of the male half after installation to prevent scratching or torn clothing. (Small needle nose pliers work well.) Parts Information The following are the button kits for service, consisting of two male and two female buttons. P/N Description 12453514 Medium Dark Oak 12453515 Graphite 12453516 Adriatic Blue 12453517 Medium Neutral (Taupe) 12453518 Medium Pewter 12453519 Dark Teal 12453520 Red Garnet 12453521 Medium Dark Neutral 12453522 Medium Dark Pewter Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C9040/41 0.2 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement Seat Belt Retractor: Service and Repair Driver Seat Retractor Side Belt Replacement Sedan Description 1. Remove the front seat belt sleeve plug (4). 2. Remove the retractor side belt sleeve bolt (3). 3. Pull on the bottom of the shoulder belt pillar guide cover (2). Remove the shoulder belt pillar guide cover. 4. Remove the shoulder belt pillar guide bolt (1). 5. Remove the center pillar upper trim panel. Refer to Roof. 6. Remove the carpet retainer. Refer to Seats and Carpet. 7. Remove the shoulder belt retractor bolt (5). 8. Lift and pull the retractor in order to disengage the retractor. 9. Remove the retractor side belt. Coupe Description 1. Remove the front seat belt sleeve plug (3). 2. Remove the retractor side belt sleeve bolt (4). 3. Pull up on the bottom of the shoulder belt pillar guide cover (2). Remove the shoulder belt pillar guide cover. 4. Remove the shoulder belt pillar guide bolt (1). 5. Remove the rear quarter trim panel. Refer to Rear Quarters. 6. Remove the seat belt intermediate guide rivet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9177 7. Remove the shoulder belt retractor bolt (5). 8. Lift and pull the retractor in order to disengage the retractor. 9. Remove the retractor side belt. Sedan Description IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Install the retractor side belt. 2. Insert the top of the retractor into the mounting slots. Pull down the top of the retractor. NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the shoulder belt retractor bolt (5). Tighten Tighten the shoulder belt retractor bolt to 42 N.m (31 lb. ft). 4. Install the carpet retainer. Refer to Seats and Carpet. 5. Install the center pillar upper trim panel. Refer to Roof. 6. Install the shoulder belt pillar guide bolt (1). Tighten Tighten the shoulder belt pillar guide bolt to 28 N.m (21 lb. ft). 7. Install the shoulder belt pillar guide cover (2). 8. Inspect the shoulder belt pillar guide cover for broken tabs. Replace any cover containing broken tabs. 9. Install the retractor side belt sleeve bolt (3). Tighten Tighten the retractor side belt sleeve bolt to 42 N.m (31 lb. ft). 10. Install the front seat belt sleeve plug (4). 11. Inspect for proper operation of the seat belt assembly. Refer to Seat Belt Checks and Emergency Locking Retractor Checks. Coupe Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9178 Description IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Install the retractor side belt. 2. Insert the top of the retractor into the mounting slots. Pull down the retractor. NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the shoulder belt retractor bolt (5). Tighten Tighten the shoulder belt retractor bolt to 42 N.m (31 lb. ft). 4. Install the seat belt intermediate guide rivet. 5. Install the rear quarter trim panel. Refer to Rear Quarters. 6. Install the shoulder belt pillar guide bolt (1). Tighten Tighten the shoulder belt pillar guide bolt to 42 N.m (31 lb. ft). 7. Install the shoulder belt pillar guide cover (2). 8. Inspect the shoulder belt pillar guide cover for broken tabs. Replace any cover containing broken tabs. 9. Install the retractor side belt sleeve bolt (4). Tighten Tighten the retractor side belt sleeve bolt to 42 N.m (31 lb. ft). 10. Install the front seat belt sleeve plug (3). 11. Inspect the retractor side belt for correct operation. Refer to Seat Belt Checks and Emergency Locking Retractor Checks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9179 Seat Belt Retractor: Service and Repair Passenger Seat Retractor Side Belt Replacement Sedan Description 1. Remove the front seat belt sleeve plug (4). 2. Remove the retractor side belt sleeve bolt (3). 3. Pull on the bottom of the shoulder belt pillar guide cover (2). Remove the shoulder belt pillar guide cover. 4. Remove the shoulder belt pillar guide bolt (1). 5. Remove the center pillar upper trim panel. Refer to Roof. 6. Remove the carpet retainer. Refer to Seats and Carpet. 7. Remove the shoulder belt retractor bolt (5). 8. Lift and pull the retractor in order to disengage the retractor. 9. Remove the retractor side belt. Coupe Description 1. Remove the front seat belt sleeve plug (3). 2. Remove the retractor side belt sleeve bolt (4). 3. Pull up on the bottom of the shoulder belt pillar guide cover (2). Remove the shoulder belt pillar guide cover. 4. Remove the shoulder belt pillar guide bolt (1). 5. Remove the rear quarter trim panel. Refer to Rear Quarters. 6. Remove the seat belt intermediate guide rivet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9180 7. Remove the shoulder belt retractor bolt (5). 8. Lift and pull the retractor in order to disengage the retractor. 9. Remove the retractor side belt. Sedan Description IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Install the retractor side belt. 2. Insert the top of the retractor into the mounting slots. Pull down the top of the retractor. NOTICE: Refer to Fastener Notice in Service Precautions. 3. Install the shoulder belt retractor bolt (5). Tighten Tighten the shoulder belt retractor bolt to 42 N.m (31 lb. ft). 4. Install the carpet retainer. Refer to Seats and Carpet. 5. Install the center pillar upper trim panel. Refer to Roof. 6. Install the shoulder belt pillar guide bolt (1). Tighten Tighten the shoulder belt pillar guide bolt to 28 N.m (21 lb. ft). 7. Install the shoulder belt pillar guide cover (2). 8. Inspect the shoulder belt pillar guide cover for broken tabs. Replace any cover containing broken tabs. 9. Install the retractor side belt sleeve bolt (3). Tighten Tighten the retractor side belt sleeve bolt to 42 N.m (31 lb. ft). 10. Install the front seat belt sleeve plug (4). 11. Inspect for proper operation of the seat belt assembly. Refer to Seat Belt Checks and Emergency Locking Retractor Checks. Coupe Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9181 Description IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Install the retractor side belt. 2. Insert the top of the retractor into the mounting slots. 3. Pull down the retractor. NOTICE: Refer to Fastener Notice in Service Precautions. 4. Install the shoulder belt retractor bolt (5). Tighten Tighten the shoulder belt retractor bolt to 42 N.m (31 lb. ft). 5. Install the seat belt intermediate guide rivet. 6. Install the rear quarter trim panel. Refer to Rear Quarters. 7. Install the shoulder belt pillar guide bolt (1). Tighten Tighten the shoulder belt pillar guide bolt to 42 N.m (31 lb. ft). 8. Install the shoulder belt pillar guide cover (2). 9. Inspect the shoulder belt pillar guide cover for broken tabs. Replace any cover containing broken tabs. 10. Install the retractor side belt sleeve bolt (4). Tighten Tighten the retractor side belt sleeve bolt to 42 N.m (31 lb. ft). 11. Install the front seat belt sleeve plug (3). 12. Inspect the retractor side belt for correct operation. Refer to Seat Belt Checks and Emergency Locking Refractor Checks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9182 Seat Belt Retractor: Service and Repair Rear Seat Retractor Side Belt Replacement Removal Procedure Description 1. Remove the rear seat cushion and the rear seat back cushion. Refer to Seats and Carpet. 2. (Coupe Only) Remove the quarter trim finish panel extension. Refer to Rear Quarters. 3. (Sedan Only) Remove the quarter upper trim finish panel. Refer to Rear Quarters. 4. Remove the quarter trim finish panel. Refer to Rear Quarters. 5. (Sedan Only) Remove the center pillar upper trim panel. Refer to Roof. 6. (Sedan Only) Remove the carpet retainer. Refer to Seats and Carpet. 7. Remove the rear window panel trim. Refer to Body Rear End. 8. Remove the rear seat anchor plate bolt. 9. Remove the rear seat belt retractor bolt (1). 10. Remove the rear seat outer retractor side belt. Installation Procedure Description IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Install the rear seat outer retractor side belt. NOTICE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor bolt (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Driver Seat Retractor Side Belt Replacement > Page 9183 Tighten Tighten the rear seat belt retractor bolt to 36 N.m (27 lb. ft). 3. Install the rear seat anchor plate bolt. Tighten Tighten the rear seat anchor plate bolt to 42 N.m (31 lb ft). 4. Install the rear window panel trim. Refer to in Body Rear End. 5. (Sedan Only) Install the carpet retainer. Refer to Seats and Carpet. 6. (Sedan Only) Install the center pillar upper trim panel. Refer to Roof. 7. Install the quarter trim finish panel. Refer to Rear Quarters. 8. (Sedan Only) Install the quarter upper trim finish panel. Refer to Rear Quarters. 9. (Coupe Only) Install the quarter trim finish panel extension. Refer to Rear Quarters. 10. Install the rear seat cushion and the rear seat back cushion. Refer to Rear Quarters. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Front End Descriminating Sensor Front End Descriminating Sensor Mounting Fasteners 10 Nm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Auxiliary Discriminating Sensor > Page 9190 Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9191 Auxiliary Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 9192 Impact Sensor: Description and Operation The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint Sensing and Diagnostic Module (SDM). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor Important Preliminary Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System. 2. Remove the Connector Position Assurance (CPA) from the inflatable restraint front end discriminating sensor harness connector. 3. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9195 4. Remove the inflatable restraint front end discriminating sensor mounting fasteners (2). 5. Remove the inflatable restraint front end discriminating sensor (1) from the hood latch support bracket (3). Installation Procedure 1. Install the inflatable restraint front end discriminating sensor (1) to the hood latch support bracket (3). NOTICE: Refer to Fastener Notice in Vehicle Damage Warnings. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Tighten Tighten fasteners to 10 N.m (89 lb. in). 3. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9196 4. Install the Connector Position Assurance (CPA) to the inflatable restraint front end discriminating sensor harness connector. 5. Enable the SIR system. Refer to Enabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9197 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations Seat Belt Buckle Switch: Component Locations At the left passenger compartment, under the left seat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Component Locations > Page 9202 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 9203 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 9223 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 9233 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9238 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9243 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 9249 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9252 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9253 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9254 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9255 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9256 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9257 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9258 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9259 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9264 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9265 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9266 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9284 Alarm Module: Service and Repair Vehicle Theft Deterrent - Component Changing Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9285 Vehicle Theft Deterrent - Controller Learning Diagram Engineers design the PASSLOCK system in order to prevent theft even if the various theft deterrent parts change. The tamper mode will engage if any of the following components change: ^ The PASSLOCK lock cylinder ^ The instrument cluster ^ The powertrain control module (PCM) If you replace any of the above components, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Diagrams Program Connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 9296 Remote Control Door Lock Receiver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair REMOVAL PROCEDURE Perform the following steps in order to open the transmitter case: 1. Insert a dime between the 2 halves of the transmitter case at the slot provided near the key ring (5) hole. 2. Twist the dime in order to open the case (6,4). 3. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side facing down. Use one 3-volt CR2032 battery or the equivalent. 2. Ensure the transmitter case seal is in the proper position. 3. Align the 2 halves of the transmitter case (6,4). 4. Snap the 2 halves of the transmitter case together. IMPORTANT: Normal battery life is approximately 2 years. Replace the batteries when the range of the transmitter begins to decrease significantly to less than approximately 7 m (23 ft). 5. Test the operation of the transmitter. If the transmitter does not function properly, resynchronization may be necessary. Refer to Transmitter Synchronization. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions Lock Cylinder Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 Lock Cylinder Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9314 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9315 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9316 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9317 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9318 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9319 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9320 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9321 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9322 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9323 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9324 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9325 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9326 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9327 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9328 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9329 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9330 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9331 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9332 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9333 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9334 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9335 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9336 Lock Cylinder Switch: Connector Views Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9337 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9338 Passlock TM Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 Theft Deterrent System Schematics: Passlock Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration Cellular Phone: Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9344 Technical Service Bulletin # 83-96-05 Date: 980701 Radio Telephone/Mobile Radio - Install/Troubleshooting File In Section: 9 - Accessories Bulletin No.: 83-96-05 Date: July, 1998 Subject: Radio Telephone/Mobile Radio (Transceiver) Installation and Troubleshooting Guidelines Models: 1990-99 Passenger Cars and Trucks This bulletin cancels and supercedes bulletin 34-92-12. Please discard Corporate Bulletin Number 34-92-12 (Section 9 - Accessories). The following information is being provided to assist in the installation and troubleshooting of Radio Telephone/Mobile Radios. Certain radio telephones or land mobile radios (also known as Radio Transceivers), or the way in which they are installed, may adversely affect various vehicle operations such as engine performance, driver information, entertainment and electrical systems. Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are NOT the responsibility of General Motors Corporation. The following are general guidelines for installing a radio transceiver in General Motors vehicles. These guidelines are intended to supplement, but not to be used in place of, detailed instructions which are the sole responsibility of the manufacturer of the involved radio transceiver. Although this document refers to passenger vehicles, the same general guidelines apply to trucks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9345 EMC TROUBLESHOOTING CHART 1. Transceiver Location Refer to the attached figures during installation. 1. Transceiver Location Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9346 a. One piece transceivers should be mounted under the dash, or on the transmission hump where they will not interfere with vehicle controls or passenger movement (See Figure 1 - One Piece Transceiver Installation). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9347 b. Locate the transceiver for remote radios on the driver's side of trunk as near to the vehicle body side as possible (See Figure 2 - Trunk Mount Transceiver Installation). Caution: To avoid possible serious injury, do not mount any transceivers, microphones, speakers, or any other item In the deployment path of a Supplemental Inflatable Restraint (SIR) or "Air Bag". 2. Antenna Installation a. Each vehicle model reacts to radio frequency energy differently. It is suggested that a magnetic-mount antenna be used to check the proposed antenna location for unwanted effects on the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9348 Antenna location is a major factor in these effects. b. The antenna should be a permanent-mount type, located in the center of the roof or center of the rear deck lid. If a magnet-mount antenna is used, care should be taken to mount the antenna in the same location as a permanent-mount type. If a disguise-mount antenna is used, great care should be taken to shield (using copper tape, etc.) any tuning network from vehicle electronics and wiring, or mount the tuning network in an area completely clear (6 inches or 15 cm away) of vehicle electronics and wiring. c. Standard metal mount antennas may be mounted on a vehicle with non-metallic body panels by two methods: 1. Mount the antenna near a metal frame section and bond the antenna mount to the frame with a short metal strap, which will provide the ground plane connection. 2. Some antenna manufacturers may offer "Ground Plane Kits" that consist of self adhesive metal foil that may be attached to the body panel to provide a ground plane connection. d. Glass Mount Antennas Glass mounted antennas should be kept as high as possible in the center of the rear window or windshield, between rear window defrost "grid lines", if present. Some vehicles use glass that contains a thin metallic layer for defrosting, or to control solar gain. GLASS MOUNT ANTENNAS WILL NOT FUNCTION WHEN MOUNTED ON THIS TYPE OF GLASS. 3. Antenna Cable Routing a. Always use high quality coax cable (95% shield coverage minimum), located away (at least 6 inches or 15 cm) from ECM's, PCM's and other electronic modules. b. Care should be taken to maintain as great a distance as possible between any vehicle wiring and coax cable. 4. Antenna Tuning It is important that the antenna be tuned properly and that reflected power be kept to less than 10% (VSWR less than 2:1) at all operating frequencies. Important: High VSWR has been shown to contribute/cause interference problems with vehicle systems. 5. Radio Wiring and Power Lead Connection Locations a. Methods to connect radio power on General Motors vehicles is dependent on the vehicle model (See Figure 1 - One Piece Transceiver Installation or Figure 2 - Trunk Mount Transceiver Installation as needed). Do not connect the negative power lead to any under-dash termination point. One of the following four methods is suggested: 1. Connect the positive and negative power leads directly to the battery terminals. GM approved methods of connecting auxiliary wiring include the adapter package illustrated in Figure 4 - Power Cable Battery Connections. Important: It is recommended that a fuse be placed in the transceiver negative power lead. This is to prevent possible transceiver damage in the event the battery to engine block ground lead is inadvertently disconnected. 2. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Connect the negative lead directly to the negative battery terminal. Important: See above important statement regarding fusing the negative power lead. 3. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9349 Connect the negative lead to the battery body connection point (usually identified by a short # 10 AWG or larger wire running from the negative battery terminal to the body of the vehicle). Important: See above important statement regarding fusing the negative power lead. 4. Connect the positive and negative leads to the Special Equipment Option (SEO) wiring provided for this purpose (if vehicle has this option). b. For One Piece Transceivers (See Figure 1 - One Piece Transceiver Installation) When ignition switch control is desired, and no SEO wiring exists, a 12 volt power contactor must be installed in the transceiver positive power lead (See Figure 3 - Power Contactor Wiring). The contactor (supplied by the installer) should be located near a proper 12 volt feed source. One lead of the contactor coil should be connected through an appropriate in-line fuse to an available accessory circuit or ignition circuit not Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9350 powered during engine cranking. The return lead of the contactor coil must return to a proper fused negative point. c. Handset or Control Units 1. Any negative power lead from a handset or control unit must return to a properly fused negative connection point. 2. It is preferable that the positive power lead for a handset, or control unit, be connected directly to a properly fused positive power feed point. If ignition switch control is desired, the handset or control unit positive power lead may be connected through an appropriate in-line fuse to an available accessory circuit (or ignition circuit not powered during engine cranking). 3. It is recommended that the handset or control unit positive and negative power leads be appropriately fused separately from the transceiver positive and negative power leads. d. Multiple Transceivers or Receivers If multiple transceivers or receivers are to be installed in the vehicle, power leads to the trunk or under the dash should be connected to covered, insulated terminal strips. All transceivers or receivers may then have their power leads connected to the insulated terminal strips. This makes a neater installation and reduces the number of wires running to the vehicle underhood area. Both positive and negative power leads should be fused. 6. Radio Wire Routing (See Figure 1 - One Piece Transceiver Installation, or Figure 2 - Trunk Mount Transceiver Installation as needed). a. The power leads (fused) should be brought through a grommeted hole (provided by the installer) in the front cowl. For trunk mounted transceivers, the cables should continue on along the driver's side door sills, under the rear seat and into the trunk through a rear bulkhead. Maintain as great a distance as possible between radio power leads and vehicle electronic modules and wiring. b. If the radio power leads need to cross the engine compartment, they should cross between the engine and the front of the vehicle. Troubleshooting Refer to the Troubleshooting Chart as needed. 1. Most vehicle-radio interaction is avoided by following the Installation Guidelines outlined above. 2. If vehicle-radio interaction is evident following radio installation, the source of the problem should be determined prior to further vehicle/radio operation. The EMC Troubleshooting Chart should help in determining the source of the vehicle-radio interaction. Parts Information P/N Description 1846855 Adapter Kit, Side Terminal Battery (consisting of Adapter Terminal, Terminal Cover, Wire Connector, Insulation Boot) 12004188 Bolt, Battery Cable Terminal 12354951 Spacer, Battery Cable Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9355 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9356 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9362 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Navigation System: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9367 Navigation System: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9368 Navigation System: Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Sound Insulators .................................................................................................................................. ...........................................................2 N.m (18 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions Compact Disc Player (CD): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9377 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9378 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9379 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9380 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9381 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9382 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9383 Compact Disc Player (CD): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9384 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9385 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9386 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9387 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9388 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9389 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9390 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Page 9408 Compact Disc Player (CD): Service and Repair A compact disc player requires no maintenance. Store compact discs in the protective containers. Store the containers away from the following hazards: ^ Extreme heat ^ Direct sunlight For the best results, use the same care in handling compact discs as with conventional records. compact discs do not require cleaning if you take the following precautions: ^ Always hold the compact disc by the edge. ^ Always return the compact disc to the case directly after playing the disc. Wipe the compact disc using a clean, dry, lint-free cloth if the disc becomes soiled by any of the following contaminants: ^ Dust ^ Dirt ^ Fingerprints Always wipe the compact disc in a straight line, from the center to the edge. Do not use solvents or abrasive cleaners on a compact disc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference Radio/Stereo: Technical Service Bulletins Radio - Delco Exchange Reference File In Section: 9 Accessories Bulletin No.: 83-96-04 Date: June, 1998 INFORMATION Subject: Delco Radio Exchange Reference Models: 1998 Passenger Cars and Trucks, 1999 Chevrolet and GMC C/K Models This bulletin cancels and supersedes Corporate Bulletin Number 72-01-O1. Please discard Corporate Bulletin Number 72-01-01 (Section 0 - General Information). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9413 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9414 This bulletin is being issued to 1.) remove radios that are not part of the Exchange Program (see list of tables). 2.) replace Corporate Bulletin Number 72-01-01 which was in the wrong section. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9415 Radio/Stereo: Technical Service Bulletins Radio Display - Error Code Diagnosis/Repair File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-005 Date: April, 2001 INFORMATION Subject: Information on Error Codes on Radio Display - Their Cause and Corrective Action Models: 1995 - 1999 Buick LeSabre 1995 - 2002 Buick Century, Park Avenue, Regal 1995 - 1996 Buick Roadmaster 1996 - 1999 Buick Riviera, Skylark 1995 - 1999 Chevrolet Lumina, Monte Carlo 1996 - 1999 Chevrolet Cavalier 1996 Chevrolet Lumina APV 1997 - 2002 Chevrolet Camaro 1998 1999 Chevrolet Venture 1997 - 2002 Chevrolet Corvette 1995 - 1999 Oldsmobile Aurora, Eighty Eight 1995 - 1997 Oldsmobile Cutlass Supreme 1999 - 2000 Oldsmobile Alero 1998 - 2001 Oldsmobile Intrigue 1995 - 1996 Oldsmobile Ninety Eight 1996 - 1999 Oldsmobile Achieva, Silhouette 1996 - 2001 Oldsmobile Bravada 1995 - 1999 Pontiac Bonneville, Sunfire 1995 - 2002 Pontiac Firebird, Grand Prix 1996 - 2000 Pontiac Grand Am 1996 - 1999 Pontiac Trans Sport 1995 - 2002 Chevrolet and GMC C/K, S/T Trucks 1996 - 2002 Chevrolet and GMC M/L Vans 1996 2000 Chevrolet and GMC G Vans This bulletin is being revised to update model years and vehicles. Please discard Corporate Bulletin Number 64-90-04A (Section 9 - Assessories). Starting in 1995, the family style radios, as well as the 12-disc LLAI and 6-disc LLAI (Low Level Audio Interface) changers and the 10-disc FMI (FM Interface) changers, have error codes to help diagnose playback mediums. Some systems will only have an ERR message and no other indicator. If an ERR message is encountered without any other identifier, you may review the following error codes to try to determine the cause of the error and correct it before sending the unit to the authorized service center. If ERR or E (and a number) appears on a customer's radio display, the number may give you a clue to the problem and corrective action. Below is a list of code numbers that may appear on the unit. Important: Not all family radios have these codes. They are dependent on the model year. Cassette Errors - E10: Tight tape error Cause(s): A restricted cassette tape transport or broken cassette drive belt Correction: Substitute a different cassette tape. If there still is an error code, service the unit at an ACDelco(R) Service Center. - E11: Broken Tape Error Cause(s): A broken cassette tape Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9416 Correction(s): Substitute a different cassette tape - E12: Communication Error Cause(s): A vehicle/radio communication problem or an internal radio communication problem. Correction(s): Disconnect the battery voltage to the radio then reconnect after a few minutes. If there still is an error, service the unit at an ACDelco(R) Service Center. - E13: Tape Communication Error Cause(s): The micro-processor is reading the speed pulses from the tape deck either too fast or too slow. Correction(s): It the tape player is still playing a cassette, try a new cassette. If there is still an error, service the unit at an ACDelco(R) Service Center. - E14: Wrapped Tape Cause(s): The tape is wrapped around the capstan. This means a tape is wound up in the tape player. This error message could appear when a CD adapter is being used. Other causes could be old or damaged tapes. Long playing (90 or 120 minute) tapes are thin and can stretch easily creating this condition. Correction(s): Try playing a known good quality tape. Remove the CD adapter. - Cln Tape Indicator Cause(s): This message appears after 50 hours of accumulated tape play. Correction(s): We suggest cleaning the tape head. Then reset the radio by depressing the eject button for five seconds. Cleaning the heads will not reset the "Cln" display. To reset the "Cln" display, push and hold the eject button for five seconds. The display will return to its normal display. CD Errors - E20: Focus Error Cause(s): The CD player cannot focus on the disc or there is an internal focus problem. Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If the problem is not corrected, service the unit at an ACDelco(R) Service Center. - E21: Tracking Error Cause(s): There is a problem with reading the disc. Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E22: Motor Error Cause(s): The CD motor is not handling the compact disc properly. Correction(s): Service or exchange the unit at an ACDelco(R) Service Center. - E23: Communications Error Cause(s): There is a vehicle/radio communication problem or an internal radio communication problem. Correction(s): Disconnect battery voltage to the radio and then reconnect after a few minutes. If there is still an error, send the unit to an ACDelco(R) Service Center. LLAI CD Changer Errors - E30: Focus Error Cause(s): The CD player cannot focus on the disc or there is an internal focus problem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9417 Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E31: Tracking Error Cause(s): There is a problem with reading the disc. Correction(s): Try cleaning the disc or try using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E32: Motor Error Cause(s): The CD motor is not handling the compact disc properly or defective magazine mounting screws are interfering with the mechanism. Correction(s): Reload the magazine. If there is still a problem, replace the magazine. If the problem continues, back out the mounting screws. If the condition is corrected, replace the screws with shorter screws or add washers to the existing screws. If this condition still exists, service the unit at an ACDelco(R) Service Center. - E33: CD Changer Communication Error Cause(s): There is a vehicle/radio communication problem or internal radio communication problem. Correction(s): Disconnect battery voltage to the radio and then reconnect after a few minutes. If there is still an error, determine if the problem is with the radio, the harness or the changer. Inspect for correct voltage at all connectors. If there is still an error, service the unit at an ACDelco(R) Service Center. - E34: Changer Door Open - E35: Changer Magazine Empty FMI 10-Disc Changer Errors - E01 Cause: This indicates a malfunction of the disc changer functions. Correction: Before sending the unit in for service, perform the following procedure: 1. Press the reset button on both the changer and the remote. The reset button on the changer is located on the front panel of the unit. It can be activated with the tip of a pin. 2. If the unit does not operate after resetting it, remove the magazine by inserting a business card between the magazine and the mechanism. The lock lever will disengage to allow the magazine to eject. 3. Make sure all CDs are in the magazine and none remain lodged in the carriage. If, upon removing the magazine, a CD is found lodged in the carriage, remove all CDs from the magazine and reinsert the magazine into the changer. 4. Press the eject button. This should cause the lodged CD to move from the carriage into the empty magazine. The magazine should automatically eject and normal operation will return. 5. If the changer fails to resume normal operation, send the unit to an ACDelco(R) Service Center. - E30 Cause: Excessive temperature Correction: Let the temperature of the changer resume to the normal range. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - Delco Exchange Reference > Page 9418 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 9419 Radio/Stereo: Locations At the center of the instrument panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 Radio/Stereo: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9435 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9436 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9437 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9438 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9439 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9440 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9441 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9442 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9443 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9444 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9445 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9446 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9447 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9448 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9449 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9450 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9451 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9452 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 9453 Radio/Stereo: Service and Repair REMOVAL PROCEDURE 1. Disable the SIR system. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 2. Disconnect the negative battery cable. 3. Remove the IP cluster trim plate. 4. Remove the screws (1). 5. Pull the radio (2) out from the instrument panel (3). 6. Disconnect the electrical connections. 7. Disconnect the antenna lead connections. 8. Remove the radio (2) from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connections to the radio (2). 2. Connect the antenna lead connections to the radio. 3. Install the radio (2) to the instrument panel (3). 4. Install the screws (1) to the instrument panel. 5. Install the IP cluster trim plate. 6. Connect the negative battery cable. 7. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations Speaker: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 9458 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 9459 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 9460 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Component Locations > Page 9461 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions Speaker: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9464 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9465 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9466 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9467 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9468 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9469 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9470 Speaker: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9471 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9472 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9473 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9474 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9475 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9476 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9477 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9478 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9479 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9480 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9481 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9482 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9483 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9484 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 Speaker: Connector Views LF Speaker LR Speaker Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 RF Speaker RF Speaker Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 RR Speaker Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker: Service and Repair Front Door REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector (1). 3. Remove the bolts (3). 4. Remove the front door speaker (2). INSTALLATION PROCEDURE 1. Install the front door speaker (2). 2. Install the bolts (3). 3. Connect the electrical connector (1). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 9500 Speaker: Service and Repair Rear Standard REMOVAL PROCEDURE 1. Remove the rear window panel trim. 2. Press the tab on the front of the rear speaker spacer (3). 3. Lift the spacer (3). 4. Pull forward on the rear speaker spacer. 5. Disconnect the rear speaker wire harness connector (1). 6. Remove the rear speaker spacer (3). 7. Remove the rear speaker screws (1). 8. Remove the rear speaker (3). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 9501 1. Install the rear speaker (3) to the rear speaker spacer (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear speaker screws (1). Tighten Tighten the rear speaker screws to 1.5 N.m (13.3 lb in). 3. Install the rear speaker wire harness connector (1). 4. Install the rear speaker spacer (3). Insert the tabs into the slots at the rear window shelf. Press down at the front of the rear speaker spacer (3) in order to snap the spacer into place. 5. Install the rear window panel trim. Convertible Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 9502 REMOVAL PROCEDURE 1. Remove the quarter trim panel. 2. Disconnect the speaker electrical connector. 3. Remove the retaining nuts (5). 4. Remove the speaker (6). 5. Remove the speaker grille (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the retaining nuts (5). Tighten Tighten the nuts to 2 N.m (18 lb in). 2. Install the speaker (6). 3. Install the speaker grille (1). 4. Connect the speaker wire harness. 5. Install the quarter trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Cassette Player - Cleaning and Maintenance Tape Player: Technical Service Bulletins Cassette Player - Cleaning and Maintenance File In Section: 08 - Body and Accessories Bulletin No.: 99-08-44-008 Date: October, 1999 INFORMATION Subject: Cassette Player Cleaning and Maintenance Models: 1998-2000 All Passenger Cars and Trucks with Cassette Tape Players Radios are being replaced and charged to warranty because the customer has commented on any one or more of the following conditions: ^ The tape plays slow. ^ The tape sounds muffled. ^ The tape sounds garbled. ^ The tape is inoperative. ^ The tape is becoming stuck in the cassette player. When the radio is returned to the repair center, the cause is found to be a dirty tape head. When a customer comes in with any of above conditions concerning their cassette player, dealers should perform the normal cassette player maintenance. Maintenance procedures are in the Owner's Manual and/or the Service Manual. The customer must be charged for this service. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions Tape Player: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9509 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9510 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9511 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9512 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9513 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9514 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9515 Tape Player: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9516 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9517 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9518 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9519 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9520 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair > Cassette Player Care and Cleaning Tape Player: Service and Repair Cassette Player Care and Cleaning General Information For the best operation of the cassette tape deck, do not use cassette tapes that have longer than 90 minutes of total playback time. Cassette tapes longer than 90 minutes may slip or jam. Head and Capstan Cleaning IMPORTANT: If a ribbon type clearer is not used, cycle the tape player cleaner at least 3 time for each cleaning. This is necessary due to the tape tension being monitored. The tape player unit will read tape cleaners without a ribbon as a broken tape. The tape player unit will reject tape cleaners without a ribbon. Clean the following 2 components on a tape player: ^ The head ^ The capstan Since you are able to reach the above parts through the tape door, leave the tape player in the vehicle. Perform this cleaning service after every 15 hours of cassette operation. Use a cotton swab dipped in ordinary rubbing alcohol in order to clean the following components: ^ The head ^ The capstan Instead of using a cotton swab, you may purchase a cleaning cassette kit. Follow the instructions on the kit in order to clean the tape player. Do not touch the tape head using magnetized tools. If the head is magnetized, every cassette you play in the player will degrade. Demagnetize the play-back head in the cassette tape deck every 50 hours of cassette play. Follow the procedure provided by the manufacturer of the demagnetizer tool in order to demagnetize the play-back head. The cartridge manufacturer performs the following services on cassette tapes: ^ Service of tapes ^ Warranty of tapes Store the dealer test tape in the container in order to keep the tape clean.Store the cartridges away from the following hazards: ^ Extreme heat ^ Direct sunlight Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair > Cassette Player Care and Cleaning > Page 9542 Tape Player: Service and Repair Ventilation Tips Clear the hood and front air inlet of the following obstructions: ^ Ice ^ Snow ^ Leaves ^ Any other obstruction If the hood and front air inlet are clear, the heater and defroster will work more efficiently. A clear hood and front air inlet will reduce the chance of fogging the following areas: ^ The inside of the windows ^ The stereo components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 9548 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9573 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9574 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9575 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9576 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9583 Alarm Module: Service and Repair Vehicle Theft Deterrent - Component Changing Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9584 Vehicle Theft Deterrent - Controller Learning Diagram Engineers design the PASSLOCK system in order to prevent theft even if the various theft deterrent parts change. The tamper mode will engage if any of the following components change: ^ The PASSLOCK lock cylinder ^ The instrument cluster ^ The powertrain control module (PCM) If you replace any of the above components, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9589 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9590 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9602 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9603 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9604 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9610 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9611 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9612 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9621 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9622 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9623 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9629 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9630 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9631 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions Lock Cylinder Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Lock Cylinder Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9662 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9663 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9664 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 Lock Cylinder Switch: Connector Views Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 Passlock TM Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Theft Deterrent System Schematics: Passlock Lock Cylinder Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Wheel Controls <--> [Steering Mounted Controls Transmitter] > Component Information > Service and Repair Steering Wheel Controls: Service and Repair Steering Wheel Control Switches Replacement REMOVAL PROCEDURE 1. Remove the steering wheel module. 2. Remove the horn plunger. 3. Remove the steering wheel redundant control switch mounting screws. 4. Disconnect the steering wheel redundant control switch electrical connector. 5. Remove the steering wheel redundant control switch from the steering wheel. INSTALLATION PROCEDURE 1. Install the steering wheel redundant control switch to the steering wheel. 2. Connect the steering wheel redundant control switch electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Wheel Controls <--> [Steering Mounted Controls Transmitter] > Component Information > Service and Repair > Page 9675 NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the steering wheel redundant control switch mounting screws. Tighten Tighten the steering wheel redundant control switch mounting screws to 2 N-m (20 lb in). 4. Install the horn plunger. 5. Install the steering wheel module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9681 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9682 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9683 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9684 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9685 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 9686 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 83-15-18A > Nov > 98 > Door Handle, Front Outside - Sticks Front Door Exterior Handle: Customer Interest Door Handle, Front Outside - Sticks File In Section: 10 - Body Bulletin No.: 83-15-18A Date: November, 1998 Subject: Front Outside Door Handle Sticks (Remove Corner of Door Handle) Models: 1998 Chevrolet Cavalier (Sedan Only) 1998 Pontiac Sunfire (Sedan Only) This bulletin is being revised to add the 1998 Pontiac Sunfire. Please discard Corporate Bulletin Number 83-15-18 (Section 10 - Body) Some customers may comment that the front outside door handle sticks or hits something when opening the door with the door glass in the full up position. Cause This condition may be caused by a corner portion of the outside door handle coming in contact with the glass sash channel. Correction 1. Remove door trim and partial water deflector. 2. Raise the door handle to the full open and file approximately 3.5 mm (1/8 in.) off the corner of the door handle (see Figure 1). Check for adequate clearance. 3. Reinstall water deflector and door trim. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 83-15-18A > Nov > 98 > Door Handle, Front Outside - Sticks > Page 9719 For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 83-15-18A > Nov > 98 > Door Handle, Front Outside - Sticks Front Door Exterior Handle: All Technical Service Bulletins Door Handle, Front Outside - Sticks File In Section: 10 - Body Bulletin No.: 83-15-18A Date: November, 1998 Subject: Front Outside Door Handle Sticks (Remove Corner of Door Handle) Models: 1998 Chevrolet Cavalier (Sedan Only) 1998 Pontiac Sunfire (Sedan Only) This bulletin is being revised to add the 1998 Pontiac Sunfire. Please discard Corporate Bulletin Number 83-15-18 (Section 10 - Body) Some customers may comment that the front outside door handle sticks or hits something when opening the door with the door glass in the full up position. Cause This condition may be caused by a corner portion of the outside door handle coming in contact with the glass sash channel. Correction 1. Remove door trim and partial water deflector. 2. Raise the door handle to the full open and file approximately 3.5 mm (1/8 in.) off the corner of the door handle (see Figure 1). Check for adequate clearance. 3. Reinstall water deflector and door trim. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 83-15-18A > Nov > 98 > Door Handle, Front Outside - Sticks > Page 9725 For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 9726 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 83-15-18A Date: 981101 Door Handle, Front Outside - Sticks File In Section: 10 - Body Bulletin No.: 83-15-18A Date: November, 1998 Subject: Front Outside Door Handle Sticks (Remove Corner of Door Handle) Models: 1998 Chevrolet Cavalier (Sedan Only) 1998 Pontiac Sunfire (Sedan Only) This bulletin is being revised to add the 1998 Pontiac Sunfire. Please discard Corporate Bulletin Number 83-15-18 (Section 10 - Body) Some customers may comment that the front outside door handle sticks or hits something when opening the door with the door glass in the full up position. Cause This condition may be caused by a corner portion of the outside door handle coming in contact with the glass sash channel. Correction 1. Remove door trim and partial water deflector. 2. Raise the door handle to the full open and file approximately 3.5 mm (1/8 in.) off the corner of the door handle (see Figure 1). Check for adequate clearance. 3. Reinstall water deflector and door trim. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 9727 For vehicles repaired under warranty, use the table. Technical Service Bulletin # 83-15-18A Date: 981101 Door Handle, Front Outside - Sticks File In Section: 10 - Body Bulletin No.: 83-15-18A Date: November, 1998 Subject: Front Outside Door Handle Sticks (Remove Corner of Door Handle) Models: 1998 Chevrolet Cavalier (Sedan Only) 1998 Pontiac Sunfire (Sedan Only) This bulletin is being revised to add the 1998 Pontiac Sunfire. Please discard Corporate Bulletin Number 83-15-18 (Section 10 - Body) Some customers may comment that the front outside door handle sticks or hits something when opening the door with the door glass in the full up position. Cause This condition may be caused by a corner portion of the outside door handle coming in contact with the glass sash channel. Correction 1. Remove door trim and partial water deflector. 2. Raise the door handle to the full open and file approximately 3.5 mm (1/8 in.) off the corner of the door handle (see Figure 1). Check for adequate clearance. 3. Reinstall water deflector and door trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > Page 9728 Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Page 9729 Front Door Exterior Handle: Service and Repair REMOVAL PROCEDURE 1. Lift the front door outside handle (1). 2. Remove the rivets (2) from the front door outside handle. 3. Remove the rod from the front door outside handle (1). 4. Remove the front door outside handle (1). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Page 9730 1. Install the rod to the front door outside handle (1). 2. Install the front door outside handle (1). 3. Lift the front door outside handle (1). 4. Install the rivets (2) to the front door outside handle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair Handle Bezel Replacement - Inside REMOVAL PROCEDURE 1. Pull the inside handle to the full open position. 2. Press on the inside handle bezel. 3. Use a flat-bladed tool in order to pry the handle bezel from the top. 4. Pull the bezel upward. 5. On the front door only, disconnect the door lock switch wire harness (2), if equipped. 6. Remove the inside bezel (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Page 9734 INSTALLATION PROCEDURE 1. On the front door only, connect the door lock switch wire harness (2), if equipped. 2. Pull the inside handle to the full open position. 3. Insert the front tab (1) on the inside bezel to the locating notch. This notch is located behind the front edge of the opening in the door trim panel. 4. Push downward on the inside bezel in order to insert the lower tab (2) behind the lower edge of the door trim panel. 5. Insert the rearmost lowest tab (3) of the inside bezel to the edge of the door trim panel. 6. Snap the top 2 tabs (4) on the inside bezel into position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched Front Door Panel: Customer Interest Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9743 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9744 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9745 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched Front Door Panel: All Technical Service Bulletins Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9751 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9752 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 9753 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9754 Front Door Panel: By Symptom Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9755 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9756 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9757 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9758 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9759 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9760 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9761 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9762 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 9763 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch Front Door Panel: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. 6. Front door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9766 INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9767 Front Door Panel: Service and Repair Door Trim Panel Replacement DOOR TRIM PANEL REPLACEMENT REMOVAL PROCEDURE TOOLS REQUIRED J 38778 Door Trim Pad Remover 1. Remove the inside handle bezel from the front door. 2. Remove the power door lock switch. 3. Remove the power window switch, if equipped. 4. Remove the window regulator handle, if equipped. 5. Remove the upper trim finish panel. 6. Remove the lower screws (3) from the front door trim panel. 7. Remove the screws (2) from the front door arm rest. 8. Using the J 38778, remove the front door trim panel fasteners from the front door inner panel (1). 9. Remove the front door trim panel (1). INSTALLATION PROCEDURE 1. Push the front door trim panel (1) inward to engage the fasteners. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the arm rest screws (2). Tighten Tighten the screws (2) to 1.5 Nm (13.3 lb in). 3. Install the lower screws (3) to the front door trim panel. Tighten Tighten the screws (3) to 1.5 Nm (13.3 lb in). 4. Install the upper trim finish panel. 5. Install the window regulator handle, if equipped. 6. Install the power window switch, if equipped. 7. Install the inside handle bezel. 8. Install the power door lock switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9768 Front Door Panel: Service and Repair Power Window Switch POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9769 Front Door Panel: Service and Repair Upper Extension Trim Panel Replacement Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9770 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9771 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9772 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9773 Front Door Panel: Service and Repair Window Regulator Handle Replacement WINDOW REGULATOR HANDLE REPLACEMENT REMOVAL PROCEDURE TOOLS REQUIRED J 9886-01 Regulator Handle Clip Remover 1. Place the door window regulator handle in the upward position. 2. Insert the J 9886-01 or an equivalent between the door window regulator handle and the door trim panel. 3. Push the J 9886-01 downward. 4. Remove the door window regulator handle (4). 5. Remove the door window regulator handle bearing plate. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 9774 1. Install the retaining clip to the door window regulator handle (4). 2. Install the door window regulator handle bearing plate. 3. Place the door window in the closed position. 4. Push the door window regulator handle (4) in order to secure the retaining clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 9779 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 9780 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch: Customer Interest Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 9794 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation Trunk / Liftgate Latch: All Technical Service Bulletins Trap Resistant Trunk Kit Function/Installation File In Section: 08 - Body and Accessories Bulletin No.: 99-08-66-002A Date: January, 2000 Subject: Trap Resistant Rear Compartment (Trunk) Kit Models: 1990-2000 Passenger Cars with Rear Compartments Except: 1990-1991 Buick Reatta 2000 Buick LeSabre 1990-1993 Cadillac Allante, Fleetwood Brougham 1997-2000 Cadillac Seville 2000 Cadillac Deville 1990 Chevrolet Caprice 1990-1991 Chevrolet Cavalier 1990-1996 Chevrolet Beretta 1990-2000 Chevrolet Metro, Prizm 1998-2000 Chevrolet Corvette 2000 Chevrolet Impala 1990-1992 Oldsmobile Toronado/Trofeo 1990-1991 Pontiac Sunbird 1990-1993 Pontiac LeMans 2000 Pontiac Bonneville This bulletin is being revised to add additional models and new part numbers. Please discard Corporate Bulletin Number 99-O8-66-002 (Section 08 - Body and Accessories). The purpose of this bulletin is to inform dealership personnel about the Trap Resistant Rear Compartment (Trunk) Kit, including the system function, necessary vehicle modifications and part numbers required to install the kit. The Trap Resistant Rear Compartment kit is composed of three main system components; one of which (the Rear Seat Tether), may or may not be needed, depending on the vehicle being retrofit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 9800 The first component of the kit is the illuminated Interior Release Handle (1). The Release Handle is mounted inside the rear compartment to the deck lid. This handle was designed so that a small child trapped in the rear compartment could use it to open the deck lid. The handle operates the deck lid latch mechanically, but is illuminated with two LED's when the deck lid is closed. The handle remains illuminated for a period of about one hour after the deck lid is closed. The LED's create a small parasitic load that will not drain the vehicle battery with normal usage. The second component of the kit is the Trap Resistant Latch (2). the Trap Resistant Latch is a modified deck lid latch designed to help prevent a child from unintentionally closing and latching the deck lid. The Trap Resistant Latch opens the rear compartment normally through all current means (key, RKE or passenger compartment release) but cannot be re-latched without the user performing a reset function. This reset function consists of pushing up on a small knob (3), while simultaneously pushing a slide mechanism to the right (4). Once the slide mechanism is fully pushed over, the small knob can be released. This function is a simple on-hand operation for an adult, but is difficult for a young child to perform. If the latch is not enabled, the deck lid will not latch and the rear compartment will not close. The third component is the Rear Seat Tether Kit. If the vehicle is equipped with a pass-through to the rear compartment and the folding rear seat can be unlatched from within the passenger compartment without the use of a key or other unlocking feature, then a Rear Seat Tether must be installed. This tether helps prevent a child from gaining access to the rear compartment of a vehicle from the passenger compartment by allowing a secondary lock of the seatback. The Rear Seat Tether employs one or two tethers (one per folding seatback), each permanently connected to a T-handle anchor mounted in the rear compartment. To lock the folding seatback, the user can partially fold the seatback and attach the tether to another T-handle anchor mounted to the seatback. When the tether is affixed to both T-handle anchors, the seat cannot be folded down. To fold down the seatback, the tether must be removed from the anchor attached to the seatback. Important: Installation of the Trap Resistant Latch on some vehicles may require sheet metal and/or trim modifications to the rear compartment striker area. These modifications should be communicated with the customer prior to installations. Also, installation of the Trap Resistant Latch requires a rear compartment lid "ajar" switch. Prior to ordering the Trap Resistant Rear Compartment Kit, inspect the old deck lid latch to see if it is equipped with an "ajar" switch. If the vehicle is not equipped with this switch, P/N 12506174 must be ordered. After completing the Trap Resistant Rear Compartment Kit installation, provide the customer with the supplemental Owner's Manual insert included in the kit and demonstrate the system function. This program is specially structured for a single purchase price to the owner. The owner is responsible to pay a maximum of $50.00 U.S.; $80.00 Canadian for parts and labor to install the complete Trap Resistant Rear Compartment Kit and Rear Seat Tether(s), if required. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 9801 Parts are currently available from GMSPO. Labor Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch: All Technical Service Bulletins Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 9806 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 83-15-15 > Aug > 98 > Rear Lid Latch - Revised Procedure for Replacement Trunk / Liftgate Latch: All Technical Service Bulletins Rear Lid Latch - Revised Procedure for Replacement File In Section: 10 - Body Bulletin No.: 83-15-15 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-8 - Revised Remove and Install Procedure for Rear Compartment Lid Latch Assembly to Add Spacer Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for rear compartment lid latch assembly (to add spacer for convertible only) in Section 10-8 of the Service Manual. Rear compartment Lid Latch Assembly Remove or Disconnect 1. Rear compartment lid latch cable assembly. 2. Unclip cable door at top of rear compartment lock release box. 3. Rear compartment lid remote release cable from lock release box. 4. Rear compartment lid latch assembly bolts. 5. Rear compartment lid latch assembly. 6. Rear compartment lid latch assembly spacer (convertible only). Install or Connect 1. Rear compartment lid latch assembly spacer (convertible only). 2. Rear compartment lid latch assembly. 3. Rear compartment lid latch assembly bolts. 4. Rear compartment lid remote release cable to lock release box. 5. Clip cable door at top of rear compartment lock release box. 6. Rear compartment lid latch cable assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation Trunk / Liftgate Latch: All Technical Service Bulletins Trap Resistant Trunk Kit Function/Installation File In Section: 08 - Body and Accessories Bulletin No.: 99-08-66-002A Date: January, 2000 Subject: Trap Resistant Rear Compartment (Trunk) Kit Models: 1990-2000 Passenger Cars with Rear Compartments Except: 1990-1991 Buick Reatta 2000 Buick LeSabre 1990-1993 Cadillac Allante, Fleetwood Brougham 1997-2000 Cadillac Seville 2000 Cadillac Deville 1990 Chevrolet Caprice 1990-1991 Chevrolet Cavalier 1990-1996 Chevrolet Beretta 1990-2000 Chevrolet Metro, Prizm 1998-2000 Chevrolet Corvette 2000 Chevrolet Impala 1990-1992 Oldsmobile Toronado/Trofeo 1990-1991 Pontiac Sunbird 1990-1993 Pontiac LeMans 2000 Pontiac Bonneville This bulletin is being revised to add additional models and new part numbers. Please discard Corporate Bulletin Number 99-O8-66-002 (Section 08 - Body and Accessories). The purpose of this bulletin is to inform dealership personnel about the Trap Resistant Rear Compartment (Trunk) Kit, including the system function, necessary vehicle modifications and part numbers required to install the kit. The Trap Resistant Rear Compartment kit is composed of three main system components; one of which (the Rear Seat Tether), may or may not be needed, depending on the vehicle being retrofit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 9816 The first component of the kit is the illuminated Interior Release Handle (1). The Release Handle is mounted inside the rear compartment to the deck lid. This handle was designed so that a small child trapped in the rear compartment could use it to open the deck lid. The handle operates the deck lid latch mechanically, but is illuminated with two LED's when the deck lid is closed. The handle remains illuminated for a period of about one hour after the deck lid is closed. The LED's create a small parasitic load that will not drain the vehicle battery with normal usage. The second component of the kit is the Trap Resistant Latch (2). the Trap Resistant Latch is a modified deck lid latch designed to help prevent a child from unintentionally closing and latching the deck lid. The Trap Resistant Latch opens the rear compartment normally through all current means (key, RKE or passenger compartment release) but cannot be re-latched without the user performing a reset function. This reset function consists of pushing up on a small knob (3), while simultaneously pushing a slide mechanism to the right (4). Once the slide mechanism is fully pushed over, the small knob can be released. This function is a simple on-hand operation for an adult, but is difficult for a young child to perform. If the latch is not enabled, the deck lid will not latch and the rear compartment will not close. The third component is the Rear Seat Tether Kit. If the vehicle is equipped with a pass-through to the rear compartment and the folding rear seat can be unlatched from within the passenger compartment without the use of a key or other unlocking feature, then a Rear Seat Tether must be installed. This tether helps prevent a child from gaining access to the rear compartment of a vehicle from the passenger compartment by allowing a secondary lock of the seatback. The Rear Seat Tether employs one or two tethers (one per folding seatback), each permanently connected to a T-handle anchor mounted in the rear compartment. To lock the folding seatback, the user can partially fold the seatback and attach the tether to another T-handle anchor mounted to the seatback. When the tether is affixed to both T-handle anchors, the seat cannot be folded down. To fold down the seatback, the tether must be removed from the anchor attached to the seatback. Important: Installation of the Trap Resistant Latch on some vehicles may require sheet metal and/or trim modifications to the rear compartment striker area. These modifications should be communicated with the customer prior to installations. Also, installation of the Trap Resistant Latch requires a rear compartment lid "ajar" switch. Prior to ordering the Trap Resistant Rear Compartment Kit, inspect the old deck lid latch to see if it is equipped with an "ajar" switch. If the vehicle is not equipped with this switch, P/N 12506174 must be ordered. After completing the Trap Resistant Rear Compartment Kit installation, provide the customer with the supplemental Owner's Manual insert included in the kit and demonstrate the system function. This program is specially structured for a single purchase price to the owner. The owner is responsible to pay a maximum of $50.00 U.S.; $80.00 Canadian for parts and labor to install the complete Trap Resistant Rear Compartment Kit and Rear Seat Tether(s), if required. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 9817 Parts are currently available from GMSPO. Labor Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > 83-15-15 > Aug > 98 > Rear Lid Latch - Revised Procedure for Replacement Trunk / Liftgate Latch: All Technical Service Bulletins Rear Lid Latch - Revised Procedure for Replacement File In Section: 10 - Body Bulletin No.: 83-15-15 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-8 - Revised Remove and Install Procedure for Rear Compartment Lid Latch Assembly to Add Spacer Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for rear compartment lid latch assembly (to add spacer for convertible only) in Section 10-8 of the Service Manual. Rear compartment Lid Latch Assembly Remove or Disconnect 1. Rear compartment lid latch cable assembly. 2. Unclip cable door at top of rear compartment lock release box. 3. Rear compartment lid remote release cable from lock release box. 4. Rear compartment lid latch assembly bolts. 5. Rear compartment lid latch assembly. 6. Rear compartment lid latch assembly spacer (convertible only). Install or Connect 1. Rear compartment lid latch assembly spacer (convertible only). 2. Rear compartment lid latch assembly. 3. Rear compartment lid latch assembly bolts. 4. Rear compartment lid remote release cable to lock release box. 5. Clip cable door at top of rear compartment lock release box. 6. Rear compartment lid latch cable assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch Release Cable: Customer Interest Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 9830 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch Release Cable: All Technical Service Bulletins Rear Compartment Lid Latch Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 9836 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9842 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9843 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9849 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9850 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Locations Fender: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Locations > Page 9862 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Suspension (Front) - Torque Specification Update Cross-Member: Technical Service Bulletins Suspension (Front) - Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 02-03-08-006 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Front Suspension Fastener Tightening Specifications Models: 1997-2002 Chevrolet Cavalier 1997-2002 Pontiac Sunfire This bulletin is being issued to revise the fastener tightening specifications in the Lower Control Arm Replacement Procedure and the Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following tightening specification has been revised: Control Arm to Crossmember Bolts (Front Bushing) - 100 N.m plus 90 degrees rotation (74 lb ft). DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Page 9868 Cross-Member: Specifications Crossmember Support Left Rear Outboard Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Right Rear Outboard Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Upper Front Bolts: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Crossmember Support Rear Inboard Bolts: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ......................................................................................................................................................... 90° Front Suspension Frame to Body Left Rear Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Front Suspension Frame to Body Right Rear Bolt: First ...................................................................................................................................................... .............................................. 110 N.m (71 ft. lbs.) Final ..................................................................... ....................................................................................................................................................... 180° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension Cross-Member: Service and Repair Front Suspension REMOVAL PROCEDURE ^ Tool Required: J 38892 Ball Joint Separator 1. Raise the vehicle. 2. If a suspension hoist is to be used: ^ Place the jack stand under the uni-body frame near the crossmember. ^ Lower the vehicle slightly so the weight of the vehicle rests on the under uni-body frame. Do not rest on the control arms or crossmember. 3. Remove the tire and wheel assemblies. Refer to WHEEL REMOVAL in TIRES AND WHEELS. 4. Disconnect the right and left wiring harnesses from the crossmember. NOTICE: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal. 5. Use the J 38892 in order to remove the ball joint (3) from the knuckle (2). 6. Remove the engine strut mount from the crossmember. Refer to ENGINE. 7. Remove the crossmember extension brace (3) bolts (2 and 4) from the lower tie bar (5). ^ Remove the front exhaust pipe. Support the catalytic converter. Refer to CATALYTIC CONVERTER in EXHAUST SYSTEM. 8. Remove the power steering gear bolts. Support the power steering gear. 9. Disconnect the brake lines from the retainers on the crossmember Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9871 10. Remove the splash shield from the crossmember. 11. Remove the stabilizer bar (3) from the crossmember (5). 12. Remove the crossmember bolts (2 through 8). 13. Remove the crossmember. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9872 14. Remove the control arms (3) from the crossmember (1). INSTALLATION PROCEDURE 1. Install the control arms (3) to the crossmember (1). Snug the bolts. 2. Install the crossmember. Finger tighten all of the bolts. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Tighten the bolts in the sequence shown below: Tighten ^ Tighten the crossmember support left rear outboard bolt to 110 Nm (71 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support right rear outboard bolt to 110 Nm (71 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support upper front bolts to 90 Nm (66 ft. lbs.) plus a 90° rotation. ^ Tighten the crossmember support rear inboard bolts to 110 Nm (71 ft. lbs.) plus a 90 rotation. Important: Do not loosen the nut any time during the installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9873 4. Install the nut (4) attaching the ball joint (3) to the steering knuckle (2). Tighten Tighten the nut to 55 Nm (41 ft. lbs.) minimum - 65 Nm (50 ft. lbs.) maximum. 5. install the cotter pin (1). 6. Install the left power steering gear bolts. Refer to POWER STEERING GEAR AND PUMP in STEERING for fastener tightening specifications. 7. Install the right power steering gear bolts. Refer to POWER STEERING GEAR AND PUMP in STEERING for fastener tightening specifications. 8. Install the front exhaust pipe. Refer to ENGINE EXHAUST in EXHAUST for tightening specifications. 9. Install the crossmember support braces. Tighten Tighten the core support bolts to the crossmember braces to 72 Nm (53 ft. lbs.). 10. Install the engine strut mount to the crossmember. Refer to ENGINE for tightening specifications. 11. Install the stabilizer bar (3) to the crossmember (5). Tighten Tighten the stabilizer shaft to support the assembly bolt to 66 Nm (49 ft. lbs.). 12. Install the splash shield to the crossmember (5). 13. Connect the brake lines to the retainers to the crossmember. 14. Install the right and left wiring harnesses to the crossmember. 15. Slightly raise the vehicle. 16. Remove the jack stand from under the crossmember. 17. Install the tire and wheel assemblies. Refer to WHEEL INSTALLATION in TIRES AND WHEELS. 18. Tighten the control arm attaching bolts, with the vehicle at curb height. Tighten ^ Tighten the control arm to crossmember bolts (front bushing) to 100 Nm (74 ft. lbs.) plus 180° rotation. ^ Tighten the control arm crossmember bolts, (vertical bushing) to 170 Nm (125 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9874 19. Check the front wheel alignment. Refer to WHEEL ALIGNMENT SPECIFICATIONS in WHEEL ALIGNMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9875 Cross-Member: Service and Repair Rear Suspension REMOVAL PROCEDURE 1. Raise and support the vehicle. 2. Support the rear axle assembly (1) with suitable jackstands. 3. Remove the both rear tires and the wheel assembly. Refer to WHEEL REMOVAL. 4. Disconnect the brake pipe at the brake pipe brackets on the axle assembly. Refer to PIPE REPLACEMENT in HYDRAULIC BRAKES. This will ensure that the axle assembly is not suspended by the brake pipes and the hoses. Plug the brake pipe openings to prevent loss of brake fluid from master cylinder. 5. Remove the lower shock absorber mount bolt (4). 6. Lower the rear axle. 7. Disconnect the parking brake at the equalizer unit. Refer to PARKING BRAKE. 8. Disconnect the rear ABS wiring connector. 9. Remove the right brake lines and the left brake lines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9876 10. Remove the axle assembly attaching bolts (1) with an assistant. 11. Remove the axle assembly (1). INSTALLATION PROCEDURE 1. Position the rear axle assembly (1) into place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Front Suspension > Page 9877 2. Loosely install the attaching bolts (1). Tighten Tighten the axle attaching bolts to 80 Nm (59 ft. lbs.), plus 120° at curb height. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. 3. Install the right brake lines and the left brake lines. 4. Connect the ABS wiring connector. 5. Connect the parking brake cable at the right rear wheel cable connector and the cable equalizer. 6. Install both springs (2) and insulators (1) while carefully raising the axle assembly and positioning the axle assembly in order to install the lower shock absorber mount stud and nut (5). 7. Lower the shock absorber mount nuts (5). Tighten Tighten the shock absorber lower attaching nut to 47 Am (35 ft. lbs.). 8. Install the left and the right side brake line bracket mount bolts to the body. Tighten Tighten the screws to 11 Nm (97 inch lbs.). 9. Install the tire and wheel assembly. Refer to WHEEL INSTALLATION. 10. Lower the vehicle. 11. Fill and bleed the rear brake system. Refer to HYDRAULIC BRAKE SYSTEM BLEEDING. 12. Adjust the parking brake. Refer to PARK BRAKE CABLE SERVICE/ADJUSTMENT. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair Arm Rest: Service and Repair REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Remove the rivets (3) which retain the front door armrest hanger plate (1). 3. Remove the front door armrest hanger plate (1). INSTALLATION PROCEDURE 1. Install the front door armrest hanger plate (1). 2. Install the rivets (3) to the front door hanger plate. 3. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet Carpet: Customer Interest Interior - Rear Footwell Wet File In Section: 08 - Body and Accessories Bulletin No.: 99-08-65-001 Date: March, 1999 TECHNICAL Subject: Rear Footwell Wet (Insert Drain Path) Models: 1995-98 Chevrolet Cavalier Convertible Only 1995-98 Pontiac Sunfire Convertible Only Condition Some customers may comment that the rear floor is wet. Cause When the vehicle is parked nose down on a steep incline, during a hard or prolonged rain, water may accumulate in the front seat belt retractor area. This could result in flooding over the poured-in-place foam and then into the passenger compartment. Correction Add the drain path, using the following procedure: 1. Remove the RH and LH rear quarter trim panels. 2. Remove the RH and LH lower seat belt retractor bolts and set the retractor aside. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet > Page 9890 3. See the figure for approximate locations for the 10 mm (3/8 in.) drain holes in the foam. Hole location is critical. 4. Install a drill stop placed approximately 32 mm (1-1/4 in.) from the end of a 3/8 drill bit. 5. Install a drill bit in a 90° degree angle drill for better clearance and drill the holes on the marks, as shown in the figure. 6. Vacuum up the foam and metal chips. 7. After drilling the holes, it is important that the appropriate anti-corrosion primer be applied. Refer to GM Approved Refinish Materials Booklet (GM4901M-D-99) for additional information. 8. Repeat for the other side. 9. Reinstall the seat belt retractors. 10. Reinstall both quarter trim panels. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time C9047 Install Drain Path 1.0 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats > Page 9896 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 9901 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 9902 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet Carpet: All Technical Service Bulletins Interior - Rear Footwell Wet File In Section: 08 - Body and Accessories Bulletin No.: 99-08-65-001 Date: March, 1999 TECHNICAL Subject: Rear Footwell Wet (Insert Drain Path) Models: 1995-98 Chevrolet Cavalier Convertible Only 1995-98 Pontiac Sunfire Convertible Only Condition Some customers may comment that the rear floor is wet. Cause When the vehicle is parked nose down on a steep incline, during a hard or prolonged rain, water may accumulate in the front seat belt retractor area. This could result in flooding over the poured-in-place foam and then into the passenger compartment. Correction Add the drain path, using the following procedure: 1. Remove the RH and LH rear quarter trim panels. 2. Remove the RH and LH lower seat belt retractor bolts and set the retractor aside. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet > Page 9907 3. See the figure for approximate locations for the 10 mm (3/8 in.) drain holes in the foam. Hole location is critical. 4. Install a drill stop placed approximately 32 mm (1-1/4 in.) from the end of a 3/8 drill bit. 5. Install a drill bit in a 90° degree angle drill for better clearance and drill the holes on the marks, as shown in the figure. 6. Vacuum up the foam and metal chips. 7. After drilling the holes, it is important that the appropriate anti-corrosion primer be applied. Refer to GM Approved Refinish Materials Booklet (GM4901M-D-99) for additional information. 8. Repeat for the other side. 9. Reinstall the seat belt retractors. 10. Reinstall both quarter trim panels. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time C9047 Install Drain Path 1.0 hr Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats > Page 9913 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 9918 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 9919 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Console and Floor Pan to Console Bracket ....................................................................................................................................................6 N.m (53 lb in) Module Assembly to Mounting Bracket Nuts ............................................................................................................................................12 N.m (106 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement Console: Service and Repair Console Replacement REMOVAL PROCEDURE 1. Open the console compartment. 2. Refer to Trim Plate Replacement - Console in order to remove one of the following components: ^ The console trim plate - automatic transmission ^ The boot - manual transmission 3. Remove the screw cover (7). 4. Remove the screws (6). 5. Remove the console (2). INSTALLATION PROCEDURE 1. Install the console (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws (6). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the screw cover (7). 4. Refer to Trim Plate Replacement - Console in order to install one of the following components: See: Trim Plate ^ The console trim plate - automatic transmission ^ The boot - manual transmission 5. Close the console compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 9925 Console: Service and Repair Power Window Switch REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 9926 Console: Service and Repair Trim Plate REMOVAL PROCEDURE 1. Gently pry upward on one of the following components in order to disengage the retainers: ^ For automatic transmission, the console trim plate (1). ^ For manual transmission, the shift lever boot (2). 2. Remove the gearshift handle. INSTALLATION PROCEDURE 1. Install the gearshift handle. 2. Align the retainers. 3. Press one of the following components into place: ^ For manual transmission, the shift lever boot (2). ^ For automatic transmission, the console trim plate (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9932 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9933 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9934 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9935 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Lamp Switch Replacement Glove Compartment: Service and Repair Instrument Panel Compartment Lamp Switch Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the instrument panel cluster trim plate. 4. Disconnect the electrical connector. 5. Compress the retainers and pull rearward on the switch. INSTALLATION PROCEDURE 1. Install the switch into the cluster trim plate. 2. Connect the electrical connectors. 3. Install the instrument panel cluster trim plate. 4. Connect the negative battery cable. 5. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Compartment Lamp Switch Replacement > Page 9940 Glove Compartment: Service and Repair Instrument Panel Compartment Replacement REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Unsnap the compartment (1) from the instrument panel (2). 4. Remove the compartment (1). INSTALLATION PROCEDURE 1. Snap the compartment (1) into the instrument panel (2). Ensure that the unit is retained. 2. Enable the SIR system. 3. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Door Trim Panel Trim Panel: Service and Repair Door Trim Panel REMOVAL PROCEDURE TOOLS REQUIRED J 38778 Door Trim Pad Remover 1. Remove the inside handle bezel from the front door. 2. Remove the power door lock switch. 3. Remove the power window switch, if equipped.. 4. Remove the window regulator handle, if equipped. 5. Remove the upper trim finish panel. 6. Remove the lower screws (3) from the front door trim panel. 7. Remove the screws (2) from the front door arm rest. 8. Using the J 38778, remove the front door trim panel fasteners from the front door inner panel (1). 9. Remove the front door trim panel (1). INSTALLATION PROCEDURE 1. Push the front door trim panel (1) inward to engage the fasteners. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the arm rest screws (2). Tighten Tighten the screws (2) to 1.5 Nm (13.3 lb in). 3. Install the lower screws (3) to the front door trim panel. Tighten Tighten the screws (3) to 1.5 Nm (13.3 lb in). 4. Install the upper trim finish panel. 5. Install the window regulator handle, if equipped. 6. Install the power window switch, if equipped. 7. Install the inside handle bezel. 8. Install the power door lock switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Door Trim Panel > Page 9945 Trim Panel: Service and Repair Upper Extension Standard REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Door Trim Panel > Page 9946 1. Install the bezel to the front door upper trim finish panel. 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Door Trim Panel > Page 9947 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9956 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9957 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9958 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Diagrams Program Connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 9969 Remote Control Door Lock Receiver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair REMOVAL PROCEDURE Perform the following steps in order to open the transmitter case: 1. Insert a dime between the 2 halves of the transmitter case at the slot provided near the key ring (5) hole. 2. Twist the dime in order to open the case (6,4). 3. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side facing down. Use one 3-volt CR2032 battery or the equivalent. 2. Ensure the transmitter case seal is in the proper position. 3. Align the 2 halves of the transmitter case (6,4). 4. Snap the 2 halves of the transmitter case together. IMPORTANT: Normal battery life is approximately 2 years. Replace the batteries when the range of the transmitter begins to decrease significantly to less than approximately 7 m (23 ft). 5. Test the operation of the transmitter. If the transmitter does not function properly, resynchronization may be necessary. Refer to Transmitter Synchronization. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front > Page 9979 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Lock Actuator LF Door Lock Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Lock Actuator > Page 9982 RF Door Lock Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Lock Actuator > Page 9983 LR Door Lock Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Lock Actuator > Page 9984 RR Door Lock Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9988 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications At the left front luggage compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Specifications > Page 9992 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch Power Door Lock Switch: Diagrams Left Front Door Lock Switch LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 9995 LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 9996 RF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9997 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power door lock switch. 2. Disconnect the wire harness (8) from the power door lock switch (9). 3. Remove the power door lock switch. INSTALLATION PROCEDURE 1. Connect the wire harness (8) to the power door lock switch. 2. Install the power door lock switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever Mirror Adjustment Handle: Customer Interest Manual Door Mirror (L/H) - Does Not Adjust With Lever File In Section: 08 - Body and Accessories Bulletin No.: 99-08-64-015 Date: September, 1999 TECHNICAL Subject: Left Hand Manual Mirror Does Not Adjust When Adjustment Lever is Moved (Adjust Lever to Align with Lever Slide) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire with Manual Mirrors This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 73-15-02 (Section 10 - Body). Condition Some owners may comment that the left hand manual mirror does not adjust when the adjustment lever is moved. Cause The adjustment lever may have become disengaged from the lever slide. Correction Caution: To avoid personal injury, do not place fingers in mirror hinge area. 1. Roll down the left door window. 2. Fold the mirror toward the front of the vehicle. Hold the mirror in position with your left hand. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever > Page 10011 3. With your right hand, move the adjustment lever handle (inside the vehicle) to align the T end of the lever with the lever slide. 4. Fold the mirror back to the original position to engage the T end of the lever with the lever slide. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time R3261 Mirror, Outside Rear View - Use published labor Replace (Manual Left) operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever Mirror Adjustment Handle: All Technical Service Bulletins Manual Door Mirror (L/H) - Does Not Adjust With Lever File In Section: 08 - Body and Accessories Bulletin No.: 99-08-64-015 Date: September, 1999 TECHNICAL Subject: Left Hand Manual Mirror Does Not Adjust When Adjustment Lever is Moved (Adjust Lever to Align with Lever Slide) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire with Manual Mirrors This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 73-15-02 (Section 10 - Body). Condition Some owners may comment that the left hand manual mirror does not adjust when the adjustment lever is moved. Cause The adjustment lever may have become disengaged from the lever slide. Correction Caution: To avoid personal injury, do not place fingers in mirror hinge area. 1. Roll down the left door window. 2. Fold the mirror toward the front of the vehicle. Hold the mirror in position with your left hand. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever > Page 10017 3. With your right hand, move the adjustment lever handle (inside the vehicle) to align the T end of the lever with the lever slide. 4. Fold the mirror back to the original position to engage the T end of the lever with the lever slide. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time R3261 Mirror, Outside Rear View - Use published labor Replace (Manual Left) operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Component Locations > Page 10025 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10035 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Paint: Customer Interest Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 10040 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10046 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Paint: All Technical Service Bulletins Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 10055 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 72-05-11 > Dec > 97 > Warranty - Rail Dust Removal & Chemical Spotting Labor Paint: All Technical Service Bulletins Warranty - Rail Dust Removal & Chemical Spotting Labor File In Section: Warranty Administration Bulletin No.: 72-05-11 Date: December, 1997 WARRANTY ADMINISTRATION Subject: Clarification of Rail Dust Removal (A5575-A5580) and Chemical Spotting (A5541-A5544) Labor Operations Models: All Past and Future Passenger Cars and Light Duty Trucks The purpose of this Warranty Administration Bulletin is to clarify the usage, limits and guidelines for the proper use of the above subject labor operations. The above subject labor operations were introduced to correct paint imperfections caused by fallout that occurred either during shipment to the dealer or within the first 12 months or 12,000 miles (20,000 kms) of vehicle ownership. GM vehicle owners are informed that although no defect in the factory applied paint causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by fallout condition within 12 months or 12,000 miles (20,000 kms) whichever occurs first. Effective with repair orders dated on or after December 1, 1997, labor operations A5575-A5580 Rail Dust Removal and A5541 through A5544 Chemical Spotting will be limited to within the first 12 months or 12,000 miles of the Base Vehicle Warranty (20,000 kms) whichever occurs first. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 72-05-11 > Dec > 97 > Warranty - Rail Dust Removal & Chemical Spotting Labor Paint: All Technical Service Bulletins Warranty - Rail Dust Removal & Chemical Spotting Labor File In Section: Warranty Administration Bulletin No.: 72-05-11 Date: December, 1997 WARRANTY ADMINISTRATION Subject: Clarification of Rail Dust Removal (A5575-A5580) and Chemical Spotting (A5541-A5544) Labor Operations Models: All Past and Future Passenger Cars and Light Duty Trucks The purpose of this Warranty Administration Bulletin is to clarify the usage, limits and guidelines for the proper use of the above subject labor operations. The above subject labor operations were introduced to correct paint imperfections caused by fallout that occurred either during shipment to the dealer or within the first 12 months or 12,000 miles (20,000 kms) of vehicle ownership. GM vehicle owners are informed that although no defect in the factory applied paint causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by fallout condition within 12 months or 12,000 miles (20,000 kms) whichever occurs first. Effective with repair orders dated on or after December 1, 1997, labor operations A5575-A5580 Rail Dust Removal and A5541 through A5544 Chemical Spotting will be limited to within the first 12 months or 12,000 miles of the Base Vehicle Warranty (20,000 kms) whichever occurs first. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10069 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10070 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 33-17-01A Date: 971201 Exhaust System - Paint Peeling from Painted Muffler Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10071 File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Labor Material Operation Labor Time Allowance Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10072 A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10073 Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10074 Disclaimer Technical Service Bulletin # 33-17-01A Date: 971201 Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10075 ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 10078 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair RADIATOR SUPPORT ASSEMBLY The radiator support assembly (Figure 2-1) consists of nine major components: four upper and five lower. The center reinforcement and left and right extensions are preassembled. This helps the technician to properly align the front structure. The upper support is serviced separately for efficient installation. The lower support is held in place with six bolts. It attaches to four brackets that are welded to the lower rails. These brackets are available as part of the lower rail service assembly or they can be ordered separately. Remove or Disconnect 1. Remove all related panels and components. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Locate, mark and drill out all factory welds. Note the number of welds for installation of the service panels. 5. Remove the damaged panels in the radiator support assembly Install or Connect 1. Prepare mating surfaces and check for proper fit of the service panels. 2. On the service panels, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service panels, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. Reinstall all related panels and components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations > Page 10086 Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Open the rear compartment. 3. Remove the left inner trim panel. 4. Disconnect one of the electrical connectors (3 or 4). 5. Remove the push pins. 6. Remove the remote control door lock receiver (1). INSTALLATION PROCEDURE 1. Install the remote control door lock receiver (1) to the rear compartment brace. 2. Install the push pins to the brace. 3. Connect the electrical connector (3 or 4). 4. Install the rear compartment trim. 5. Close the rear compartment. 6. Connect the negative battery cable. 7. Reprogram the new receiver to the transmitter(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10093 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header Convertible Top Frame: Customer Interest Convertible Top - Water Leak at Front Header File In Section: 08 - Body and Accessories Bulletin No.: 99-08-57-019 Date: May, 1999 TECHNICAL Subject: Water Leak at Front Header (Measure/Remove Material, install Shims) Models: 1995-99 Chevrolet Cavalier (Convertible Only) 1995-99 Pontiac Sunfire (Convertible Only) Condition Some customers may comment that there is a water leak at the outboard corners of the convertible top interior. Correction ^ Strikers are adjusted rearward to allow the front leading edge of bow to contact the seal In plain view (distance from header to convertible top should be 10-13 mm (25/54 - 1/2). The front edge of the convertible top (or # 1 bow) must contact the seal. No visible gaps allowed (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10104 ^ Check under the striker for shim. One shim is required under # 1 bow strikers (see Figure 2). Add shim if necessary. Important: The new top cover single seam design built after June, 1998 requires one shim per striker. Two piece top cover single seam (see Figure 2). ^ Tops built prior to June, 1998 with the header welt, P/N 12365667 were built with two shims per striker. Three piece top cover (see Figure 3). Important: This procedure requires the use of an upholstery type or automotive trim stapler by a technician knowledgeable in replacement of the convertible top cover material. If you intend to sublet vehicles requiring this repair to an independent automotive trim shop, please supply them with this Service Bulletin. ^ The top cover installation over the front leading edge of the # 1 bow, must be free of wrinkles for good seal to the header. See highlighted area in Figure 2. ^ The outboard edge binding must be trimmed 12.7-19.05 mm (1/2 - 1/4 in) long and stapled at the edges with stainless steel staples (see Figure 2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10105 Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header Convertible Top Frame: All Technical Service Bulletins Convertible Top - Water Leak at Front Header File In Section: 08 - Body and Accessories Bulletin No.: 99-08-57-019 Date: May, 1999 TECHNICAL Subject: Water Leak at Front Header (Measure/Remove Material, install Shims) Models: 1995-99 Chevrolet Cavalier (Convertible Only) 1995-99 Pontiac Sunfire (Convertible Only) Condition Some customers may comment that there is a water leak at the outboard corners of the convertible top interior. Correction ^ Strikers are adjusted rearward to allow the front leading edge of bow to contact the seal In plain view (distance from header to convertible top should be 10-13 mm (25/54 - 1/2). The front edge of the convertible top (or # 1 bow) must contact the seal. No visible gaps allowed (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10111 ^ Check under the striker for shim. One shim is required under # 1 bow strikers (see Figure 2). Add shim if necessary. Important: The new top cover single seam design built after June, 1998 requires one shim per striker. Two piece top cover single seam (see Figure 2). ^ Tops built prior to June, 1998 with the header welt, P/N 12365667 were built with two shims per striker. Three piece top cover (see Figure 3). Important: This procedure requires the use of an upholstery type or automotive trim stapler by a technician knowledgeable in replacement of the convertible top cover material. If you intend to sublet vehicles requiring this repair to an independent automotive trim shop, please supply them with this Service Bulletin. ^ The top cover installation over the front leading edge of the # 1 bow, must be free of wrinkles for good seal to the header. See highlighted area in Figure 2. ^ The outboard edge binding must be trimmed 12.7-19.05 mm (1/2 - 1/4 in) long and stapled at the edges with stainless steel staples (see Figure 2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10112 Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Motor > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Motor > Component Information > Locations > Page 10116 LH Folding Top Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Relay > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Relay > Component Information > Locations > Page 10120 Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch Bypass Switch (Folding Top) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch > Page 10126 Folding Top Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: Customer Interest Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: All Technical Service Bulletins Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely Sunroof / Moonroof Motor: Customer Interest Body - Sunroof Won't Open/Close Completely Bulletin No.: 03-08-67-009A Date: March 08, 2004 TECHNICAL Subject: Sunroof Will Not Open or Close Completely (Replace Sunroof Motor) Models: 1998-2004 Chevrolet Cavalier 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Grand Am 1998-2004 Pontiac Sunfire Supercede: This bulletin is being revised to change the part number. Please discard Corporate Bulletin Number 03-08-67-009 (Section 08 - Body and Accessories) Condition Some customers may comment that the sunroof will not open or will not close completely. Cause This condition may be due to the sunroof motor. Follow the procedure below for diagnostics. Sunroof Motor Diagnosis 1. Remove the headliner as necessary. 2. Jumper Pin # 1 and Pin # 8 on the sunroof express module. If more access is needed, push the module towards the motor and unlock it from the bracket. Refer to the Illustration above. Note: Avoid operating the sunroof glass to the full open position. Since the limit switch has a jumper across it, there will be no indication to the sunroof module to stop the glass at the full open soft stop. The glass can slide past the full open position, possibly damaging the sunroof assembly and/or the roof. 3. With the ignition ON, push the sunroof switch to the close position to fully seat the sunroof. If this action fully closes the sunroof, replace the sunroof motor only. Refer to the Sunroof Motor Replacement below. If this action does not fully close the sunroof, go to Diagnostic Starting Point-Roof in the service manual. 4. Remove the jumper and re-lock the sunroof express module back into its bracket. Sunroof Motor Replacement Service Procedure Note: This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10149 timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly. 1. Clip the tie straps and remove the express module by sliding it towards the motor to unlock it from the slots provided in the module. 2. Disconnect the wire harness from the express module, power supply, and switch. 3. remove the sunroof motor/actuator bolts(2) from the sunroof motor/actuator. 4. Remove the sunroof motor/actuator from the sunroof module. 5. Remove the sunroof glass. 6. Make sure the sunroof lift arms are aligned by inserting a pin in the front sunroof glass attachment hole to the lift arm cam. If you can insert a large paper clip through the two, it is aligned. Refer to the illustration above. 7. If the arms are not aligned, push the arms with a screwdriver at the location shown. Refer to the illustration above. Important: Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position. 8. Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by preforming the following steps: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10150 8.1. The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. Refer to the illustration above. 8.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify that all timing marks are aligned. 9. Position the sunroof motor/actuator to the sunroof module. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fasteners. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the sunroof motor/actuator. Tighten Tighten the sunroof motor/actuator to 3 N.m (27 lb in). 11. Connect the wire harness connectors to the express module. Slide the express module into the slots and lock it. Reconnect the power supply and the switch to the express module. Secure the wire harness to the drive tube and return tube with tie wraps. 12. Install the headliner as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10151 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely Sunroof / Moonroof Motor: All Technical Service Bulletins Body - Sunroof Won't Open/Close Completely Bulletin No.: 03-08-67-009A Date: March 08, 2004 TECHNICAL Subject: Sunroof Will Not Open or Close Completely (Replace Sunroof Motor) Models: 1998-2004 Chevrolet Cavalier 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Grand Am 1998-2004 Pontiac Sunfire Supercede: This bulletin is being revised to change the part number. Please discard Corporate Bulletin Number 03-08-67-009 (Section 08 - Body and Accessories) Condition Some customers may comment that the sunroof will not open or will not close completely. Cause This condition may be due to the sunroof motor. Follow the procedure below for diagnostics. Sunroof Motor Diagnosis 1. Remove the headliner as necessary. 2. Jumper Pin # 1 and Pin # 8 on the sunroof express module. If more access is needed, push the module towards the motor and unlock it from the bracket. Refer to the Illustration above. Note: Avoid operating the sunroof glass to the full open position. Since the limit switch has a jumper across it, there will be no indication to the sunroof module to stop the glass at the full open soft stop. The glass can slide past the full open position, possibly damaging the sunroof assembly and/or the roof. 3. With the ignition ON, push the sunroof switch to the close position to fully seat the sunroof. If this action fully closes the sunroof, replace the sunroof motor only. Refer to the Sunroof Motor Replacement below. If this action does not fully close the sunroof, go to Diagnostic Starting Point-Roof in the service manual. 4. Remove the jumper and re-lock the sunroof express module back into its bracket. Sunroof Motor Replacement Service Procedure Note: This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10157 timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly. 1. Clip the tie straps and remove the express module by sliding it towards the motor to unlock it from the slots provided in the module. 2. Disconnect the wire harness from the express module, power supply, and switch. 3. remove the sunroof motor/actuator bolts(2) from the sunroof motor/actuator. 4. Remove the sunroof motor/actuator from the sunroof module. 5. Remove the sunroof glass. 6. Make sure the sunroof lift arms are aligned by inserting a pin in the front sunroof glass attachment hole to the lift arm cam. If you can insert a large paper clip through the two, it is aligned. Refer to the illustration above. 7. If the arms are not aligned, push the arms with a screwdriver at the location shown. Refer to the illustration above. Important: Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position. 8. Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by preforming the following steps: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10158 8.1. The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. Refer to the illustration above. 8.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify that all timing marks are aligned. 9. Position the sunroof motor/actuator to the sunroof module. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fasteners. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the sunroof motor/actuator. Tighten Tighten the sunroof motor/actuator to 3 N.m (27 lb in). 11. Connect the wire harness connectors to the express module. Slide the express module into the slots and lock it. Reconnect the power supply and the switch to the express module. Secure the wire harness to the drive tube and return tube with tie wraps. 12. Install the headliner as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 10159 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Motor: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Motor: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 10165 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Motor: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 10166 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Motor: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 10172 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Motor: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 10173 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Back: Customer Interest Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10190 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10191 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Back: All Technical Service Bulletins Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10197 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10198 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure Seat Back: All Technical Service Bulletins Seatback Striker, Rear - Add Remove/Install Procedure File In Section: 10 - Body Bulletin No.: 83-10-95 Date: February, 1998 SERVICE MANUAL UPDATE Subject: Section 10-13 - Add Remove/Install Procedure for Rear Seatback Striker Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to add a new service procedure to Section 10-13 of the Service Manual. All 1995-98 Chevrolet Cavalier and Pontiac Sunfire convertibles each have four shims (two per attached bolt) located behind the rear seat striker. The striker is a carryover from the coupe; however, shimming the striker is convertible only. Please add the following procedure to Section 10-13 of the Service Manual. Rear Seatback Striker (Convertible Only) Figure 1 Remove or Disconnect 1. Rear seatback. 2. Boot center section. 3. Rear shelf carpet from the bottom of the closeout panel, as necessary. 4. Bolts, seat striker and the two shims. Install or Connect 1. Two shims, seat striker and the bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure > Page 10203 Tighten Tighten rear seat striker bolts to 10 N.m (88.5 lb in.). 2. Rear shelf carpet to the bottom of the closeout panel. 3. Boot center section. 4. Rear seatback. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10209 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10210 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10216 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10217 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10222 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10223 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10224 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10225 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10226 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Cushion: Customer Interest Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10235 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10236 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Cushion: All Technical Service Bulletins Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10242 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10243 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10249 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10250 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10256 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10257 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch Bypass Switch (Folding Top) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Diagrams > Convertible Top Bypass Switch > Page 10264 Folding Top Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications Power Door Lock Switch: Specifications At the left front luggage compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Specifications > Page 10268 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch Power Door Lock Switch: Diagrams Left Front Door Lock Switch LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 10271 LF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Front Door Lock Switch > Page 10272 RF Door Lock Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10273 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power door lock switch. 2. Disconnect the wire harness (8) from the power door lock switch (9). 3. Remove the power door lock switch. INSTALLATION PROCEDURE 1. Connect the wire harness (8) to the power door lock switch. 2. Install the power door lock switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Component Locations > Page 10278 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: Customer Interest Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: All Technical Service Bulletins Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Brake Switch And Cruise Control Brake Switch At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10300 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10301 Brake Switch (Cruise Control): Adjustments IMPORTANT: If you do not adjust the switches properly, the cruise control system may not work properly. You may not adjust the release switch assembly and the stoplamp switch assembly until after you assemble the brake booster pushrod to the brake pedal assembly. Adjust the cruise control release switch and the stoplamp switch together. 1. Press the brake pedal assembly. Insert the switch assembly and stoplamp switch assembly into the retainers until fully seated. 2. Slowly release the brake pedal assembly back to its fully retracted position. The release switch assembly will move within its retainers to the "adjusted" position. Use the following brake pedal assembly travel distances to check for properly adjusted release and stoplamp switch assemblies: ^ Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 in) brake pedal assembly travel. Take the measurement at the centerline of the brake pedal assembly pad. ^ Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 in) after the cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10302 Brake Switch (Cruise Control): Service and Repair REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connector(s). 3. Pull the switch rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket (from the forward side). 2. With the brake or clutch pedal depressed, insert the switch into the retainer until the switch seats on the retainer. You may hear audible "clicks" as the ribbed portion of the switch pushes forward through the retainer. 3. Connect the wiring harness connector(s). 4. Adjust the switch in the following manner: 4.1. Pull the brake or clutch pedal fully rearward against the pedal stop until you can not hear audible "clicks". The switch moves in the retainer. This movement provides adjustment. 4.2. Release the brake or the clutch pedal. Repeat the above in order to ensure that you have properly adjusted the switch. 5. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations Cruise Control Clutch And Clutch Pedal Switches At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10306 Cruise Control Clutch Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Control Module Assembly Bracket to Front of Dash ....................................................................................................................................25 N.m (18 lb ft) Control Module Assembly Bracket to Strut Tower .......................................................................................................................................25 N.m (18 lb ft) Control Module Assembly to Bracket ..........................................................................................................................................................10 N.m (89 lb in) Module Assembly to Mounting Bracket Nuts ............................................................................................................................................12 N.m (106 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10310 Cruise Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10311 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10312 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) Cruise Control Module: Service and Repair Cruise Control Module Replacement (LD9) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the module retaining nuts. 5. Remove the module (1) from the mounting bracket. 6. Remove the module assembly from the front of the dash. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the front of the dash. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Connect the electrical connector to the module. 3. Install the cruise control cable. 4. Adjust the cruise control cable. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) > Page 10315 Cruise Control Module: Service and Repair Cruise Control Module Replacement (LN2) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the retaining nuts from the mounting studs. 5. Remove the module assembly (1) from the right strut tower. 6. Remove the module assembly from the mounting bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the mounting bracket. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Install the module assembly to strut tower. 3. Install the nuts. Tighten Tighten the nuts to 25 Nm (18 lb ft). 4. Connect the electrical connector to the module. 5. Install the cruise control cable. 6. 6. Adjust cruise control cable. 7. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments 1. Depress the tabs on the cruise control cable in order to disengage the adjustment lock. Use long nose pliers. The cable will move freely in and out of the adjuster when you disengage the lock. 2. Hold the TBI at the closed position. IMPORTANT: Do not remove the engagement lock from the cable. If the engagement lock separates from the cruise control cable, you must replace the cruise control cable. 3. Engage the adjustment lock. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly Cruise Control Switch: Service and Repair Cruise Control Switch Assembly REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connectors. 3. Pull the clutch pedal switch (1) rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket from the forward side. 2. Depress the clutch pedal (3). 3. Insert the switch into the retainer until the switch seats on the retainer. 4. Connect the wiring harness to the clutch pedal switch. 5. Use the following steps in order to adjust the switch: 5.1. Pull the clutch pedal fully rearward against the pedal stop until you cannot hear the clicks. 5.2. Move the switch in the retainer in order to adjust the switch. 5.3. Release the clutch pedal. 5.4. Repeat the procedure, if necessary, in order to properly adjust the switch. 6. Connect the wiring harness connectors. 7. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly > Page 10323 Cruise Control Switch: Service and Repair Headlamp/Turn Signal/Cruise Control/Hazard Switch REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications Cruise Control Module: Specifications Control Module Assembly Bracket to Front of Dash ....................................................................................................................................25 N.m (18 lb ft) Control Module Assembly Bracket to Strut Tower .......................................................................................................................................25 N.m (18 lb ft) Control Module Assembly to Bracket ..........................................................................................................................................................10 N.m (89 lb in) Module Assembly to Mounting Bracket Nuts ............................................................................................................................................12 N.m (106 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10328 Cruise Control Module: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10329 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Specifications > Page 10330 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) Cruise Control Module: Service and Repair Cruise Control Module Replacement (LD9) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the module retaining nuts. 5. Remove the module (1) from the mounting bracket. 6. Remove the module assembly from the front of the dash. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the front of the dash. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Connect the electrical connector to the module. 3. Install the cruise control cable. 4. Adjust the cruise control cable. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Service and Repair > Cruise Control Module Replacement (LD9) > Page 10333 Cruise Control Module: Service and Repair Cruise Control Module Replacement (LN2) REMOVAL PROCEDURE The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor in order to vary the throttle with each different cruise control mode. The module assembly is not serviceable. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the cruise control cable. 3. Disconnect the electrical connector from the module assembly. 4. Remove the retaining nuts from the mounting studs. 5. Remove the module assembly (1) from the right strut tower. 6. Remove the module assembly from the mounting bracket. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: Do not pre-tap screws to the module without mounting a bracket in between the module and the screw. The added length of the screw may damage the cruise control module. 1. Install the module assembly (1) to the mounting bracket. Tighten Tighten the nuts to 12 N.m (106 lb in). 2. Install the module assembly to strut tower. 3. Install the nuts. Tighten Tighten the nuts to 25 Nm (18 lb ft). 4. Connect the electrical connector to the module. 5. Install the cruise control cable. 6. 6. Adjust cruise control cable. 7. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Brake Switch And Cruise Control Brake Switch At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10338 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10339 Brake Switch (Cruise Control): Adjustments IMPORTANT: If you do not adjust the switches properly, the cruise control system may not work properly. You may not adjust the release switch assembly and the stoplamp switch assembly until after you assemble the brake booster pushrod to the brake pedal assembly. Adjust the cruise control release switch and the stoplamp switch together. 1. Press the brake pedal assembly. Insert the switch assembly and stoplamp switch assembly into the retainers until fully seated. 2. Slowly release the brake pedal assembly back to its fully retracted position. The release switch assembly will move within its retainers to the "adjusted" position. Use the following brake pedal assembly travel distances to check for properly adjusted release and stoplamp switch assemblies: ^ Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 in) brake pedal assembly travel. Take the measurement at the centerline of the brake pedal assembly pad. ^ Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 in) after the cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10340 Brake Switch (Cruise Control): Service and Repair REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connector(s). 3. Pull the switch rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket (from the forward side). 2. With the brake or clutch pedal depressed, insert the switch into the retainer until the switch seats on the retainer. You may hear audible "clicks" as the ribbed portion of the switch pushes forward through the retainer. 3. Connect the wiring harness connector(s). 4. Adjust the switch in the following manner: 4.1. Pull the brake or clutch pedal fully rearward against the pedal stop until you can not hear audible "clicks". The switch moves in the retainer. This movement provides adjustment. 4.2. Release the brake or the clutch pedal. Repeat the above in order to ensure that you have properly adjusted the switch. 5. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations Cruise Control Clutch And Clutch Pedal Switches At the left lower instrument panel, below the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10344 Cruise Control Clutch Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly Cruise Control Switch: Service and Repair Cruise Control Switch Assembly REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the wiring harness connectors. 3. Pull the clutch pedal switch (1) rearward in order to remove the switch from the retainer in the bracket. INSTALLATION PROCEDURE 1. Install the retainer into the bracket from the forward side. 2. Depress the clutch pedal (3). 3. Insert the switch into the retainer until the switch seats on the retainer. 4. Connect the wiring harness to the clutch pedal switch. 5. Use the following steps in order to adjust the switch: 5.1. Pull the clutch pedal fully rearward against the pedal stop until you cannot hear the clicks. 5.2. Move the switch in the retainer in order to adjust the switch. 5.3. Release the clutch pedal. 5.4. Repeat the procedure, if necessary, in order to properly adjust the switch. 6. Connect the wiring harness connectors. 7. Install the sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Switch Assembly > Page 10349 Cruise Control Switch: Service and Repair Headlamp/Turn Signal/Cruise Control/Hazard Switch REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored ABS Light: Testing and Inspection ABS Warning Lamp Always ON, No DTC's Stored ABS Indicator On No DTC Set Wiring Diagram ABS Indicator On No DTC Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBC and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 10355 With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ABS warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 10356 ABS Light: Testing and Inspection ABS Warning Lamp OFF Constantly, No DTC's Stored ABS Indicator Off No DTC Set Wiring Diagram ABS Indicator Off No DTC Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The following conditions may cause an intermittent malfunction: ^ A poor connection Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > ABS Warning Lamp Always ON, No DTC's Stored > Page 10357 ^ Rubbed-through wire insulation ^ A broken wire inside the insulation The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed, refer to Instrument Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ABS warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information Audible Warning Device: Description and Operation General Information The Audible Wainings System is controlled by the Multi-Function Alarm Module and sounds a chime to bring attention to several conditions. These conditions are: 1. Key is in the Ignition Cylinder (with door open). 2. Seat Belt is not fastened. 3. Headlights are on (with door open). The Multi-Function Alarm Module also controls a battery run down protection feature. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10363 Audible Warning Device: Description and Operation Fasten Belts Chime With the Ignition Switch in "RUN," "BULB TEST" or START," voltage is applied through the ALARM Fuse to Connectorector C1 terminal "M" of the Multi-Function Alarm Module. With the LH front seat belt unbuckled, Connectorector C1 terminal "K" of the Multi-Function Alarm Module is grounded through the Seat Belt Switch. The fasten belts chime sounds for 4 to 8 seconds. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10364 Audible Warning Device: Description and Operation Fasten Belts Indicator The Fasten Belts Indicator is controlled by the Instrument Panel Cluster (IPC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10365 Audible Warning Device: Description and Operation Key-In-Ignition Chime Voltage is applied at all times to Connector C2 terminal D of the Multi-Function Alarm Module through the INT LAMP Fuse. When the key is in the ignition and LH front door is open, Connector C1 terminal H and terminal E of the Multi-Function Alarm Module are grounded. This sounds the chime. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10366 Audible Warning Device: Description and Operation General Information The Audible Wainings System is controlled by the Multi-Function Alarm Module and sounds a chime to bring attention to several conditions. These conditions are: 1. Key is in the Ignition Cylinder (with door open). 2. Seat Belt is not fastened. 3. Headlights are on (with door open). The Multi-Function Alarm Module also controls a battery run down protection feature. Fasten Belts Chime With the Ignition Switch in "RUN," "BULB TEST" or START," voltage is applied through the ALARM Fuse to Connectorector C1 terminal "M" of the Multi-Function Alarm Module. With the LH front seat belt unbuckled, Connectorector C1 terminal "K" of the Multi-Function Alarm Module is grounded through the Seat Belt Switch. The fasten belts chime sounds for 4 to 8 seconds. Fasten Belts Indicator The Fasten Belts Indicator is controlled by the Instrument Panel Cluster (IPC). Key-In-Ignition Chime Voltage is applied at all times to Connector C2 terminal D of the Multi-Function Alarm Module through the INT LAMP Fuse. When the key is in the ignition and LH front door is open, Connector C1 terminal H and terminal E of the Multi-Function Alarm Module are grounded. This sounds the chime. Lamps-ON Chime The Multi-Function Alarm Module sounds the Lamps-on Chime when the following three conditions are met: 1. The Battery voltage at the Multi-Function Alarm Module connector C1 terminal D indicates that the Parklamps or Headlamps are on. 2. 0 volts at the Multi-Function Alarm Module connector C1 terminal M indicates that the Ignition Switch is in OFF, ACCY, or LOCK. 3. Ground at the Multi-Function Alarm Module connector C1 terminal H indicates that the LH Front Door is open. Battery Run Down Protection The Battery Run Down Protection Feature is made up of two independent features: The Inadvertent Power Control, and the Courtesy Lamps Control. Inadvertent Power Control The Inadvertent Power Control output of the Multi-Function Alarm Module supplies voltage to these lamps: Courtesy, Header, rear Quarter, Vanity Mirror, Reading, I/P Compartment and Luggage Compartment. For more information, refer to Interior Lights. Courtesy Lamps Control The Courtesy Lamps Control output of the Multi-Function Alarm Module supplies ground to the Courtesy and Dome lamps. For more information, refer to Interior Lights. Power Output Diagnostic Mode There is a Power Output Diagnostic Mode in the Multi-Function Alarm Module that can be used to run a quick check on the operation of the Parasitic Power Control, the Courtesy Lights Control and the Inadvertent Power Control outputs. It is activated after all of the following actions have been performed: ^ Set Park Brake ^ Close all doors ^ Turn Ignition Switch to RUN and, before 15 seconds pass, perform these steps. Open the RH front door - Cycle the Headlamp Switch from OFF to PARK three times. During normal operations (no trouble found), the Multi-Function Alarm Module will flash the interior lamps until the ignition is turned off. In the event an internal short is found in the Multi-Function Alarm Module, the module will chime as follows: ^ One chime every three seconds - Inadvertent output failure ^ Two chimes every three seconds - Courtesy output failure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures Audible Warning Device: Diagnostic Trouble Code Tests and Associated Procedures System Check System Diagnosis - Audible Warning System ^ Perform the System Check and refer to the Symptom Table for the appropriate diagnostic procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10369 Audible Warning Device: Symptom Related Diagnostic Procedures Chart #1 All Warning Chimes Are Inoperative Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10370 Chart #2 Key-In-Ignition Chime Does Not Operate Properly (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10371 Chart #2 Key-In-Ignition Chime Does Not Operate Properly (Part 2 Of 2) Chart #3 Fasten Belts Chime Does Not Operate Properly (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10372 Chart #3 Fasten Belts Chime Does Not Operate Properly (Part 2 Of 2) Troubleshooting Hints - Audible Warning System PERFORM BEFORE BEGINNING SYSTEM DIAGNOSIS NOTE: The Multi-Function Alarm Module will go to sleep 3 or 20 minutes after key off depending if the vehicle has travelled over 24 km (15 miles). Until the Multi-Function Alarm Module goes to sleep, it will draw 60-80ma. Once the Multi-Function Alarm Module goes to sleep, the amperage draw will drop to 3-15 ma. ^ For diagnosis of the Fasten Belts Indicator, refer to Instrument Panel Cluster (IPC) Microprocessor. ^ Check for a broken (or partially broken) wire inside of the insulation which could cause system failure but prove good in a continuity/voltage check (refer to General Troubleshooting Procedures under Diagrams/Diagnostic Aids). ^ Check for proper installation of after market electronic equipment which may affect the integrity of other systems (refer to General Troubleshooting Procedures under Diagrams/Diagnostic Aids). ^ Refer to System Diagnosis. ^ Check the ALARM Fuse, INSTH/PCM Fuse, and the INT LAMP Fuse by visual inspection. ^ The Lights-On chime is inoperative, check for a poor connection at the Convenience Center connector C1 terminal D or an open in circuit 32. If OK, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. ^ The Fasten Belts chime does not operate, check for a short to battery or an open in circuit 238 or circuit 150. If OK, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. ^ The Multi-Function Alarm Module chimes one time every three seconds during Power Output Diagnostic Mode, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. ^ The Multi-Function Alarm Module chimes two times every three seconds during the Power Output Diagnostic Mode, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10373 ^ The Multi-Function Alarm Module chimes three times every three seconds during Power Output Diagnostic Mode, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. ^ Interior Lamps Fuse opens continuously, remove the Multi-Function Alarm Module connector C2 and check for short to ground in circuits 340, 1732, and 1733. If OK, replace the Multi-Function Alarm Module, refer to Multi-Function Alarm Assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations > Component Locations Audible Warning Device Control Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations > Component Locations > Page 10378 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10381 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10382 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10383 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10384 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10385 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10386 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10387 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10388 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10389 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10390 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10391 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10392 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10393 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10394 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10395 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10396 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10397 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10398 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10399 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10400 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10401 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10402 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10403 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10404 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10405 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10406 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10407 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10408 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10409 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10410 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10411 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10412 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10413 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10414 Audible Warning Device Control Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Remove the left sound insulator. 3. Remove the retaining nuts (4) from the alarm module (5). 4. Remove the multifunction alarm assembly (5) from the convenience center. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly (5) to the convenience center. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts (4) to the alarm module (5). Tighten Tighten the nuts to 6 N-m (53 lb in). 3. Install the left sound insulator. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10419 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10420 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10421 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10422 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10423 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10424 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10425 Brake Warning Indicator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10426 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10427 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10428 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10429 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10430 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10431 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10432 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10433 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10434 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10435 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10436 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10437 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10438 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10439 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10440 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10441 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10442 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10443 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10444 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10445 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10446 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10447 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10448 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10449 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10450 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Page 10451 Brake Warning Indicator: Description and Operation The standard brake system uses a single red BRAKE warning light. The light is located in the instrument panel cluster. When the ignition switch is in the START position, the BRAKE warning light should glow and turn off when the ignition switch returns the RUN position. The following conditions will activate the BRAKE light: ^ The parking brake is applied. The light should be on whenever the parking brake is applied and the ignition switch is on. ^ The fluid level is low. A low fluid level in the master cylinder will turn the BRAKE light on. For electrical diagnosis on the BRAKE warning system, refer to Brake Lamp (Warning Indicator). Antilock Brake System The antilock brake system uses two indicator lamps, a red BRAKE warning lamp and an amber ANTILOCK lamp. Both of the lamps are located in the instrument panel cluster. The lamps should activate under the following normal conditions: ^ When the ignition is turned to the RUN position, prior to starting the engine, the amber ANTILOCK lamp should fun ON. ^ As the engine is cranked, the red BRAKE lamp and the amber ANTILOCK lamp should come ON. ^ When the engine is started, both lamps should be OFF. For further information regarding the warning lamp operation for the Antilock brake system, refer to ABS Light. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Customer Interest for Cigarette Lighter: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cigarette Lighter: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Page 10465 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Page 10466 Cigar Lighter Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Page 10467 Cigarette Lighter: Service and Repair REMOVAL PROCEDURE 1. Remove the cluster trim plate. 2. Disconnect the electrical connector. 3. Remove the base from the retainer (4). 4. Turn the base counterclockwise. 5. Remove the lighter housing (3) from the trim plate (1). INSTALLATION PROCEDURE 1. Install the lighter housing (3) to the trim plate (1). 2. Install the base to the retainer (4). 3. Connect the electrical connector. 4. Install the instrument panel cluster trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10473 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10474 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10475 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10476 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Component Locations Dimmer Switch: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Component Locations > Page 10483 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Component Locations > Page 10484 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Component Locations > Page 10485 Dimmer Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Component Locations > Page 10486 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 10487 Dimmer Switch: Diagrams Panel Dimmer Switch Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Page 10488 Dimmer Switch: Testing and Inspection For electrical diagnosis of the column mounted dimmer switch system, refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10493 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10494 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10495 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10496 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10497 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 10498 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10499 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10500 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10501 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10506 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10507 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10508 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10509 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10510 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10511 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, The AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system malfunction. Description 5. Remove the AIR BAG Fuse from the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 6. Remove the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. 7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10517 8. Disconnect the driver yellow 2-way connector located near the base of the steering column. 9. Remove the Connector Position Assurance (CPA) from the passenger yellow 2-way connector located near the base of the steering column. 10. Disconnect the passenger yellow 2-way connector located near the base of the steering column. Enabling the SIR System 1. Remove the key from the ignition switch. 2. Connect the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10518 3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way connector located near the base of the steering column. 4. Connect the driver yellow 2-way connector located near the base of the steering column. 5. Install the Connector Position Assurance (CPA) to the driver yellow 2-way connector located near the base of the steering column. 6. Install the left sound insulator. Refer to Sound Insulators in Instrument Panel, Gauges and Console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10519 Description 7. Install the AIR BAG fuse to the fuse block. Refer to Fuse Block in Instrument Panel, Gauges and Console. 8. Install the left IP end cap. Refer to IP End Caps in Instrument Panel, Gauges and Console. 9. Staying well away from both air bags, turn the ignition switch to the RUN position. 9.1. The AIR BAG warning lamp will flash seven times. 9.2. The AIR BAG warning lamp will then turn OFF. 10. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10520 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint Sensing and Diagnostic Module (SDM) maintains a reserve energy supply. The reserve energy supply provides deployment power for the air bags. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn OFF the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Instrument Panel Circuit Board > Component Information > Technical Service Bulletins > Instrument Panel Cluster - Revised Replacement Instrument Panel Circuit Board: Technical Service Bulletins Instrument Panel Cluster - Revised Replacement File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-009 Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Instrument Panel Cluster (IPC) Replacement Models: 1995 Chevrolet Cavalier with 2.3L Engine (VIN D - RP0 LD2) 1995 Pontiac Sunfire with 2.3L Engine (VIN D - RP0 LD2) 1996-1999 Chevrolet Cavalier 1996-1999 Pontiac Sunfire This bulletin is being issued to add a step to the Instrument Panel Cluster (IPC) Replacement procedure in the Instrument Panel and Console sub-section of the Service Manual. Please add this information to your Service Manual. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. It is necessary to reprogram the theft deterrent system after IPC replacement. The final step of the installation procedure of the Instrument Panel Cluster (IPC) Replacement procedure should read "Disengage the theft deterrent tamper mode. Refer to PASSLOCK Changing - Components Description in Theft Deterrent." DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection For diagnosis of the system, Refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero Odometer: Customer Interest Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 99-08-49-012 > Sep > 99 > Trip Odometer - Resets to Zero > Page 10536 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 99-08-49-012 > Sep > 99 > Trip Odometer Resets to Zero Odometer: All Technical Service Bulletins Trip Odometer - Resets to Zero File In Section: 08 - Body and Accessories Bulletin No.: 99-08-49-012 Date: September, 1999 TECHNICAL Subject: Trip Odometer Resets (Install Diode) Models: 1998 Chevrolet Cavalier with Compressed Natural Gas (CNG) fuel option Condition Some customers may comment that the trip odometer resets to zero. Cause The CNG vehicle's fuel system electrical components back feed, with 12 volts, Circuit # 1020 for several seconds after key off. This voltage disrupts communication between the PCM and the I/P cluster and the trip odometer mileage information is lost before it is stored in the memory of the PCM. Correction Install the diode assembly; P/N 52369504, using the following procedure: 1. Remove the secondary lock (comb) from the diode assembly and save for reuse. 2. Find the grey 10 way connector (1), located between the radiator and where the radiator hose attaches to the engine. 3. Separate the grey 10 way connector and remove the comb from the connector top half (the one with the female terminals). 4. Using the terminal removal tool, GM 12094429, remove the pink wire from cavity C of the grey 10 way connector. 5. Insert the pink wire, removed in the previous step, into cavity B of the diode assembly connector and reinstall the comb. 6. Insert the pink wire from cavity C of the diode assembly into cavity C of the 10 way connector and reinstall the comb. 7. Reconnect both halves of the 10 way connector. 8. Attach the diode assembly to the side of the 10 way connector, using a plastic tie strap or tape. 9. Remove the ground stud nut from the top forward transaxle to the engine mounting bolt and slip the diode assembly wire eyelet over the stud and reinstall the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 99-08-49-012 > Sep > 99 > Trip Odometer Resets to Zero > Page 10542 Tighten Tighten to 25 N.m (18 lb ft). Parts Information Part Number Description 52369504 Diode Assembly, Ignition Wiring Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6360 Diode Assembly, Ignition 0.3 hr Wiring - Install Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10546 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10547 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 10552 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Component Locations Audible Warning Device Control Module: Component Locations At the right front of the passenger compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Component Locations > Page 10558 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10561 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10562 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10563 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10564 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10565 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10567 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10568 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10569 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10570 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10571 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10572 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10573 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10574 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10575 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10576 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10577 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10578 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10579 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10580 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10581 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10582 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10593 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10594 Audible Warning Device Control Module: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Remove the left sound insulator. 3. Remove the retaining nuts (4) from the alarm module (5). 4. Remove the multifunction alarm assembly (5) from the convenience center. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly (5) to the convenience center. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts (4) to the alarm module (5). Tighten Tighten the nuts to 6 N-m (53 lb in). 3. Install the left sound insulator. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations Dimmer Switch: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 10602 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 10603 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 10604 Dimmer Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Component Locations > Page 10605 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 10606 Dimmer Switch: Diagrams Panel Dimmer Switch Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Page 10607 Dimmer Switch: Testing and Inspection For electrical diagnosis of the column mounted dimmer switch system, refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10612 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10613 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10614 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10615 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10616 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 10617 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10618 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10619 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10620 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10625 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10626 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10627 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10628 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10629 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10630 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection For diagnosis of the system, Refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Component Locations Parking Brake Warning Switch: Component Locations Component Location Views Parking Brake Switch Location Left hand center of console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Component Locations > Page 10638 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information Speedometer Head: Technical Service Bulletins Instruments - Speedometer Accuracy Information INFORMATION Bulletin No.: 08-08-49-011B Date: September 05, 2008 Subject: Information On Speedometer Accuracy Models: 1997-1999 GM Passenger Cars And Trucks 2004-2009 Cadillac XLR 2005-2009 Chevrolet Corvette 2007-2009 GMC Acadia Supercede: This bulletin is being revised to add the GMC Acadia. Please discard Corporate Bulletin Number 08-08-49-011A (Section 08 - Body and Accessories). The speedometer used on most GM vehicles are of the Air-Core design. This is a moving needle operated by a magnetic coil. Because there is no direct mechanical linkage, there is some variation in accuracy that cannot be eliminated. Digital readout devices, such as some speedometer displays and Head-Up Displays (HUD), are direct readouts of the Vehicle Speed Sensor (VSS) and their accuracy is much greater. Tire size, tread life and inflation may cause some variation in the readings. In addition, the Tech 2(R) reads the VSS directly and is quite accurate. Questions on speedometer accuracy can usually be resolved by comparing the speedometer reading to the Tech 2 while driving. The table shown above lists allowable speedometer variations. Any Air-Core speedometer that reads within these limits should not be returned for service. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator ON With No DTCS Set ETS Off Indicator On No DTCs Set Wiring Diagram ETS Off Indicator On No DTCs Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The ETS OFF indicator will be ON and the Enhanced Traction System will be disabled whenever the scan tool is connected to the DLC with the ignition switch is in the RUN position. The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 10647 portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Panel Cluster for further serial data link information. Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ETS OFF warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 10648 Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator OFF No DTCS Set ETS Off Indicator Off No DTCs Set Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 10649 ETS Off Indicator Off No DTCs Set CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM\A and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper warning indicator commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. Refer to Instrument Panel luster for further serial data link information. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool, as described in "Enhanced Diagnostics". The following conditions may cause an intermittent malfunction: ^ A poor connection ^ Rubbed-through wire insulation ^ A broken wire inside the insulation Use the Lamp Test function of the Scan Tool in order to turn the indicator on while looking for an intermittent malfunction in the ETS OFF warning indicator circuitry. Thoroughly inspect any circuitry that may cause the intermittent complaint for the following conditions: ^ Backed out terminals ^ Improper mating ^ Broken locks ^ Improperly formed or damaged terminals ^ Poor terminal-to-wiring connections ^ Physical damage to the wiring harness IMPORTANT: Zero the J 39200 test leads before making any resistance measurements. Refer to the J 39200 user's manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10659 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 10660 Backup Lamp Switch (Manual) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10665 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Component Locations > Page 10668 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10671 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10672 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10673 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10674 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10675 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10676 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10677 Brake Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10678 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10679 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10680 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10681 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10682 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10683 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10684 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10685 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10686 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10687 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10688 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 Brake Lamp: Connector Views LH Tail/Stop/Turn Lamp RH Tail/Stop/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 Turn/Hazard/Front Marker/Front Park Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Switch And Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 Brake Light Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10720 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10721 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10722 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10723 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10724 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10725 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10726 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10727 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10728 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10734 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10735 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10736 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10737 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10738 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10739 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10740 Brake Light Switch: Connector Views Brake Switch (C1) Brake Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10741 Turn/Hazard/Front Marker/Front Park Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10742 Brake Light Switch: Adjustments REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling the switch towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. 3. For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. 4. Turn the switch 90 degrees clockwise in order to lock into position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10743 5. Install the electrical connection. 6. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10744 Brake Light Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10745 ^ For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. ^ For adjustment of the stop lamp, refer to Stop Lamp Adjustment. 3. Turn the switch 90 degrees clockwise in order to lock into position. 4. Install the electrical connection. 5. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations > Page 10750 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10753 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10754 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10755 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10756 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10757 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10758 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10759 Center Mounted Brake Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10760 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10761 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10762 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10763 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10764 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10765 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10766 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10767 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10768 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10769 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10770 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10771 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10772 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10773 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10774 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10775 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10776 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10777 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10778 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10779 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10780 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10781 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10782 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10783 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10784 Center Mounted Brake Lamp: Connector Views High Mounted Stoplamp Assembly (C1) High Mounted Stoplamp Assembly (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10785 High Mounted Stoplamp Assembly (W/T43) High Mounted Stoplamp Assembly (W/T43) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10786 High Mounted Stop/Stop-Turn Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 10787 Center Mounted Brake Lamp: Service and Repair REMOVAL PROCEDURE 1. Remove the rear window panel trim. 2. From the rear compartment, push up on the high mount stoplamp ratchet mechanism. 3. Slide the high mount stoplamp (1) forward. 4. Disconnect the high mount stoplamp wire harness connector. 5. Remove the high mount stoplamp (1). INSTALLATION PROCEDURE 1. Connect the high mount stoplamp wire harness connector. 2. Use the following procedure in order to install the high mount stoplamp (1): 2.1. Insert the tabs into the slots at the rear window shelf. 2.2. Push forward on the high mount stoplamp until the high mount stoplamp is secure against the back window. 2.3. Install the rear window panel trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations > Page 10792 Ashtray Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Door Lamp > Component Information > Service and Repair Door Lamp: Service and Repair REMOVAL PROCEDURE 1. From the rear of the dome lamp lens, insert a flat bladed tool (1) between the dome lamp lens and the headlining trim finish panel (2). 2. Use the flat bladed tool in order to push the tab at the rear of the dome lamp lens forward. Disengage the tab from the headlining trim finish panel. 3. Pull the dome lamp lens rearward in order to disengage the 2 tabs at the front of the dome lamp lens. INSTALLATION PROCEDURE 1. Insert the 2 forward tabs on the dome lamp lens into the appropriate holes in the headlining trim finish panel (2). 2. Push at the rear of the dome lamp lens until the rear tab is fully seated in the headlining trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Glove Box Lamp: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 10799 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 10800 IP Compartment Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations > LH Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations > LH > Page 10805 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp Interior Light Switch: Diagrams Courtesy/Reading Lamp LH Courtesy/Reading Lamp RH Courtesy/Reading Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp > Page 10808 Interior Light Switch: Diagrams Courtesy/Reading Lamp Switch LH Courtesy/Reading Lamp Switch RH Courtesy/Reading Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations DAYTIME RUNNING LAMP RELAY Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 10813 Component Location Views The Daytime Running Lamp Relay is located in the Left Fuse block. The Left Fuse Block is located behind lower LH side of Instrument Panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Component Locations Dimmer Switch: Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Component Locations > Page 10820 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Component Locations > Page 10821 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Component Locations > Page 10822 Dimmer Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Component Locations > Page 10823 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 10824 Dimmer Switch: Diagrams Panel Dimmer Switch Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 10825 Dimmer Switch: Testing and Inspection For electrical diagnosis of the column mounted dimmer switch system, refer to ELECTRICAL DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Dome Lamp Override Switch Replacement REMOVAL PROCEDURE 1. Remove the headlining trim finish panel. 2. Remove the reading lamp switch tabs from the dome lamp housing. 3. Remove the reading lamp. INSTALLATION PROCEDURE 1. Install the reading lamp switch to the dome lamp housing. 2. Install the headlining trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10834 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10835 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10836 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10837 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10838 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 10839 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10840 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10841 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10842 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 10848 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10849 Fog/Driving Lamp Relay: Diagrams Fog Lamp Cutoff Relay Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 10853 Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10858 Brake Switch And Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10859 Turn/Hazard Flasher Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the left side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10863 Hazard Warning Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10864 Turn/Hazard Headlamp Switch (C2) Turn/Hazard Headlamp Switch (C3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10865 Hazard Warning Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL PROCEDURE 1. Remove the upper air intake splash shield. 2. Remove the lamp assembly. 3. Remove the socket. Complete the following steps. 3.1. Turn the socket. 3.2. Pull out the socket CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: ^ Turn off the lamp switch and allow the bulb to cool before changing the bulb. Leave the lamp switch off until the bulb change is complete. ^ Always wear eye protection when changing a halogen bulb. ^ Handle the bulb only by its base. Avoid touching the glass. ^ Do not drop or scratch the bulb. ^ Keep dirt and moisture off the bulb. ^ Place the used bulb in the new bulb's carton and dispose of it properly. ^ Keep halogen bulbs out of the reach of children 4. Use the following procedure in order to disconnect the electrical connector: 4.1. With one hand, grip the wiring harness end of the bulb that the electrical wires enter. Do not grip the wires. Important: Do not grip the bulb glass. 4.2. With the other hand, grip the base of the bulb. 4.3. Carefully pull the bulb base apart from the wiring harness. INSTALLATION PROCEDURE 1. Connect the bulb socket to the lamp harness connector. 2. Align the bulb flange notch with the lamp housing key way. 3. Insert the bulb into the lamp housing. 4. Turn the bulb into the housing until it is retained. 5. Install the lamp assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Component Locations Horn Relay: Component Locations HORN RELAY Convenience Center The Horn Relay is located in the Convenience Center. The Convenience Center is located at the right front of the passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Component Locations > Page 10882 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Component Locations > Page 10887 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10890 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10891 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10892 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10893 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10894 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10895 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10896 License Plate Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10897 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10898 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10899 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10900 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10901 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10902 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10903 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10904 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10905 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10906 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10907 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10908 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10909 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10910 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10911 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10912 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10913 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10914 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10915 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10916 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10917 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10918 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10919 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10920 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10921 License Plate Lamp: Connector Views License Lamp License Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10922 Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 10923 License Plate Lamp: Service and Repair REMOVAL PROCEDURE 1. Turn the license plate bulb (1) counter-clockwise. 2. Remove the license plate bulb (1) from the socket. INSTALLATION PROCEDURE 1. Align the tabs of the license plate and the socket. 2. Turn the license plate bulb (1) clockwise in order to install the bulb into the socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams Map Light: Diagrams LH Courtesy/Reading Lamp RH Courtesy/Reading Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Marker Lamp, LH Front Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Marker Lamp, LH Front > Page 10931 LH Rear Fascia (RH Similar) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 10932 Marker Lamp: Diagrams RR Side Marker Lamp LR Side Marker Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 10933 LF Marker Lamp RF Marker Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Park/Turn Signal/Side Marker Lamp Replacement Marker Lamp: Service and Repair Park/Turn Signal/Side Marker Lamp Replacement REMOVAL PROCEDURE 1. Remove the headlamp assembly. 2. Remove the socket from the side marker lamp assembly (3). 3. Remove the side marker lamp retaining nuts. 4. Remove the side marker lamp from the front fender (2). INSTALLATION PROCEDURE 1. Install the side marker lamp to the front fender (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the side marker lamp retaining nuts. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the socket to the side marker lamp assembly (3). 4. Install the headlamp assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Park/Turn Signal/Side Marker Lamp Replacement > Page 10936 Marker Lamp: Service and Repair Side Marker Lamp Replacement REMOVAL PROCEDURE 1. Remove the screw (2). 2. Remove the lamp housing (3). 3. Remove the rear side marker lamp bulb from the rear side marker lamp (3). INSTALLATION PROCEDURE 1. Install the rear side marker lamp bulb to the socket. 2. Install the lamp housing (3). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (2). Tighten Tighten the screw 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10941 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Page 10942 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Page 10943 Parking Lamp: Diagrams RF Park/Turn Lamp LF Park/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Page 10944 LF Park/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement Parking Lamp: Service and Repair Park/Turn Signal Lamp Replacement REMOVAL PROCEDURE 1. Remove the front inner wheel housing. 2. Remove the park/turn signal lamp retaining nuts. 3. Push the lamp assembly outward. 4. Disconnect the electrical connector. 5. Remove the socket by completing the following steps: 5.1. Depress the locking tab. 5.2. Rotate the socket (3) counter-clockwise. 6. Remove the bulb from the socket (3). INSTALLATION PROCEDURE 1. Install the bulb to the socket (3). 2. Install the socket (3) into the park/turn signal lamp assembly. Turn the socket (3) counterclockwise. 3. Connect the electrical connector. 4. Install the park/turn signal lamp. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the park/turn signal lamp retaining screws. Tighten Tighten the screws to 2 N.m (18 lb in). 6. Install the front inner wheel housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement > Page 10947 Parking Lamp: Service and Repair Park/Turn Signal/Side Marker Lamp Replacement REMOVAL PROCEDURE 1. Remove the headlamp assembly. 2. Remove the socket from the side marker lamp assembly (3). 3. Remove the side marker lamp retaining nuts. 4. Remove the side marker lamp from the front fender (2). INSTALLATION PROCEDURE 1. Install the side marker lamp to the front fender (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the side marker lamp retaining nuts. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the socket to the side marker lamp assembly (3). 4. Install the headlamp assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations DAYTIME RUNNING LAMP RELAY Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 10952 Component Location Views The Daytime Running Lamp Relay is located in the Left Fuse block. The Left Fuse Block is located behind lower LH side of Instrument Panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 10957 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10958 Fog/Driving Lamp Relay: Diagrams Fog Lamp Cutoff Relay Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations Horn Relay: Component Locations HORN RELAY Convenience Center The Horn Relay is located in the Convenience Center. The Convenience Center is located at the right front of the passenger compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations > Page 10963 Convenience Center Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10968 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10969 Backup Lamp Switch (Manual) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Switch And Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10975 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10976 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10977 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10978 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10979 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10980 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10981 Brake Light Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10982 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10983 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10984 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10985 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10986 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10987 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10988 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10989 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10990 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10991 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10992 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10993 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10994 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10995 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10996 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10997 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10998 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10999 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11000 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11001 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11002 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11003 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11004 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11005 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11006 Brake Light Switch: Connector Views Brake Switch (C1) Brake Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11007 Turn/Hazard/Front Marker/Front Park Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11008 Brake Light Switch: Adjustments REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling the switch towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. 3. For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. 4. Turn the switch 90 degrees clockwise in order to lock into position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11009 5. Install the electrical connection. 6. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11010 Brake Light Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the driver side sound insulator. 2. Remove the electrical connection. 3. Disconnect the brake switch retainer (2), grasping and turning 90 degrees counter clockwise and pulling towards the rear of the vehicle. INSTALLATION PROCEDURE 1. Insert the stop lamp switch (2) into the retainer until the switch body seats on the retainer. 2. Pull the brake pedal (3) upward against the internal pedal stop. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11011 ^ For the diagnosis of the stop light circuit, refer to Electrical Diagnosis. ^ For adjustment of the stop lamp, refer to Stop Lamp Adjustment. 3. Turn the switch 90 degrees clockwise in order to lock into position. 4. Install the electrical connection. 5. Install the drivers side sound insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Dome Lamp Override Switch Replacement REMOVAL PROCEDURE 1. Remove the headlining trim finish panel. 2. Remove the reading lamp switch tabs from the dome lamp housing. 3. Remove the reading lamp. INSTALLATION PROCEDURE 1. Install the reading lamp switch to the dome lamp housing. 2. Install the headlining trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Door Switch: Component Locations Door Jamb Switch, LH Front Component Location Views At the left front door jamb (right switch similar) Door Jamb Switch, LH Rear Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11019 Component Location Views At the left rear door (right switch similar) Door Jamb Switch, RH Front At the right front door jamb (left switch similar) Door Jamb Switch, RH Rear At the right rear door jamb Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11020 Door Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11021 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11022 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11023 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 11024 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11025 Door Switch: Diagrams LF Door Jamb Switch LR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11026 RF Door Jamb Switch RF Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 11027 RR Door Jamb Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11031 Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the left side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11035 Hazard Warning Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11036 Turn/Hazard Headlamp Switch (C2) Turn/Hazard Headlamp Switch (C3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11037 Hazard Warning Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > LH Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > LH > Page 11045 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp Interior Light Switch: Diagrams Courtesy/Reading Lamp LH Courtesy/Reading Lamp RH Courtesy/Reading Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Courtesy/Reading Lamp > Page 11048 Interior Light Switch: Diagrams Courtesy/Reading Lamp Switch LH Courtesy/Reading Lamp Switch RH Courtesy/Reading Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Trunk Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Turn Signal Switch Assembly ............................................................................................................................................................. 3.4 N.m (30 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11055 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11056 Turn Signal Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11057 Turn/Hazard Headlamp Switch (C3) Turn/Hazard Headlamp Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11058 Turn Signal Switch: Testing and Inspection This diagnosis covers mechanical problems only. Refer to ELECTRICAL DIAGNOSIS for turn signal switch electrical diagnosis. TURN SIGNAL WILL NOT STAY IN TURN POSITION Inspect ^ Damaged turn signal switch. TURN SIGNAL WILL NOT CANCEL Inspect ^ Loose turn signal switch mounting screws. ^ Broken turn signal switch. ^ Damaged canceling cam. TURN SIGNAL DIFFICULT TO OPERATE Inspect ^ Damaged turn signal switch. ^ Loose turn signal switch mounting screws. TURN SIGNAL WILL NOT INDICATE LANE CHANGE Inspect ^ Damaged turn signal switch. ^ Pinched turn switch wires. ^ Burned out turn indicator panel lights. HAZARD SWITCH CANNOT BE TURNED OFF Inspect ^ Damaged turn signal switch. HAZARD SWITCH WILL NOT STAY ON OR DIFFICULT TO TURN OFF Inspect ^ Loose turn signal switch. ^ Hazard switch interference with other components. ^ Foreign material interference to hazard slider lever. ^ Damaged turn signal switch. ^ Misaligned column covers. NO TURN SIGNAL LIGHTS Inspect ^ Damaged turn signal bulbs. ^ Electrical short in wiring harness. ^ Inoperative turn signal flasher. ^ Loose turn signal switch connector. ^ Damaged turn signal switch. TURN INDICATOR LIGHTS ON, BUT NOT FLASHING Inspect ^ Bulb burnt out, either in front or back or side of vehicle. ^ Inoperative turn signal flasher. ^ Inoperative turn signal switch. TURN INDICATOR LIGHTS OFF AND NOT FLASHING Inspect ^ Damaged turn signal switch. ^ Burned-out or damaged turn signal bulb. ^ High resistance connection to ground at bulb socket. ^ Loose turn signal switch connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11059 ^ Faulty turn signal flasher. NO TURN INDICATOR PANEL LIGHTS Inspect ^ Burned out bulbs or opens, grounds in the wiring harness from the front turn signal bulb socket to the indicator lights. TURN SIGNAL LIGHTS FLASH VERY RAPIDLY OR VERY SLOWLY Inspect ^ Burned out or damaged turn signal bulbs. ^ Loose turn signal connection. ^ Faulty turn signal flasher. ^ Pinched or grounded wiring harness. HAZARD SIGNAL LIGHTS WILL NOT FLASH - TURN SIGNAL FUNCTIONS NORMALLY Inspect ^ Blown fuse. ^ Inoperative hazard warning flasher. ^ Loose turn signal switch connection. ^ Damaged turn signal switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 11060 Turn Signal Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 11065 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Locations > Component Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Locations > Component Locations > Page 11068 Tail Lamp: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Locations > Component Locations > Page 11069 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11072 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11073 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11074 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11075 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 Tail Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11089 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11090 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11091 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11092 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11093 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11094 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11095 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11096 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11097 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11098 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 Tail Lamp: Connector Views LH Tail/Stop/Turn Lamp RH Tail/Stop/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11105 Tail Lamp: Service and Repair REMOVAL PROCEDURE 1. Disconnect the tail lamp wire harness sockets (6). 2. Remove the tail lamp nut (1). 3. Remove the tail lamp (5). INSTALLATION PROCEDURE 1. Install the tail lamp (5). 2. Align the tail lamp to the deck lid applique. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the tail lamp nut (1). Tighten Tighten the tail lamps nuts to 5 N.m (44 lb in). 4. Connect the tail lamp wire harness sockets (6). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Trunk Lamp Switch > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Brake Switch And Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 11114 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 11115 Turn/Hazard Flasher Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 11120 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Auxiliary Turn Lamp, RF Turn Signal Lamp: Locations Auxiliary Turn Lamp, RF Right fender Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Auxiliary Turn Lamp, RF > Page 11123 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Page 11124 Turn Signal Lamp: Diagrams LH Tail/Stop/Turn Lamp RH Tail/Stop/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Page 11125 LF Park/Turn Lamp RF Park/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Page 11126 LF Park/Turn Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement Turn Signal Lamp: Service and Repair Park/Turn Signal Lamp Replacement REMOVAL PROCEDURE 1. Remove the front inner wheel housing. 2. Remove the park/turn signal lamp retaining nuts. 3. Push the lamp assembly outward. 4. Disconnect the electrical connector. 5. Remove the socket by completing the following steps: 5.1. Depress the locking tab. 5.2. Rotate the socket (3) counter-clockwise. 6. Remove the bulb from the socket (3). INSTALLATION PROCEDURE 1. Install the bulb to the socket (3). 2. Install the socket (3) into the park/turn signal lamp assembly. Turn the socket (3) counterclockwise. 3. Connect the electrical connector. 4. Install the park/turn signal lamp. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the park/turn signal lamp retaining screws. Tighten Tighten the screws to 2 N.m (18 lb in). 6. Install the front inner wheel housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement > Page 11129 Turn Signal Lamp: Service and Repair Park/Turn Signal/Side Marker Lamp Replacement REMOVAL PROCEDURE 1. Remove the headlamp assembly. 2. Remove the socket from the side marker lamp assembly (3). 3. Remove the side marker lamp retaining nuts. 4. Remove the side marker lamp from the front fender (2). INSTALLATION PROCEDURE 1. Install the side marker lamp to the front fender (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the side marker lamp retaining nuts. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the socket to the side marker lamp assembly (3). 4. Install the headlamp assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Turn Signal Switch Assembly ............................................................................................................................................................. 3.4 N.m (30 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11133 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11134 Turn Signal Switch: Diagrams Turn/Hazard Headlamp Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11135 Turn/Hazard Headlamp Switch (C3) Turn/Hazard Headlamp Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11136 Turn Signal Switch: Testing and Inspection This diagnosis covers mechanical problems only. Refer to ELECTRICAL DIAGNOSIS for turn signal switch electrical diagnosis. TURN SIGNAL WILL NOT STAY IN TURN POSITION Inspect ^ Damaged turn signal switch. TURN SIGNAL WILL NOT CANCEL Inspect ^ Loose turn signal switch mounting screws. ^ Broken turn signal switch. ^ Damaged canceling cam. TURN SIGNAL DIFFICULT TO OPERATE Inspect ^ Damaged turn signal switch. ^ Loose turn signal switch mounting screws. TURN SIGNAL WILL NOT INDICATE LANE CHANGE Inspect ^ Damaged turn signal switch. ^ Pinched turn switch wires. ^ Burned out turn indicator panel lights. HAZARD SWITCH CANNOT BE TURNED OFF Inspect ^ Damaged turn signal switch. HAZARD SWITCH WILL NOT STAY ON OR DIFFICULT TO TURN OFF Inspect ^ Loose turn signal switch. ^ Hazard switch interference with other components. ^ Foreign material interference to hazard slider lever. ^ Damaged turn signal switch. ^ Misaligned column covers. NO TURN SIGNAL LIGHTS Inspect ^ Damaged turn signal bulbs. ^ Electrical short in wiring harness. ^ Inoperative turn signal flasher. ^ Loose turn signal switch connector. ^ Damaged turn signal switch. TURN INDICATOR LIGHTS ON, BUT NOT FLASHING Inspect ^ Bulb burnt out, either in front or back or side of vehicle. ^ Inoperative turn signal flasher. ^ Inoperative turn signal switch. TURN INDICATOR LIGHTS OFF AND NOT FLASHING Inspect ^ Damaged turn signal switch. ^ Burned-out or damaged turn signal bulb. ^ High resistance connection to ground at bulb socket. ^ Loose turn signal switch connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11137 ^ Faulty turn signal flasher. NO TURN INDICATOR PANEL LIGHTS Inspect ^ Burned out bulbs or opens, grounds in the wiring harness from the front turn signal bulb socket to the indicator lights. TURN SIGNAL LIGHTS FLASH VERY RAPIDLY OR VERY SLOWLY Inspect ^ Burned out or damaged turn signal bulbs. ^ Loose turn signal connection. ^ Faulty turn signal flasher. ^ Pinched or grounded wiring harness. HAZARD SIGNAL LIGHTS WILL NOT FLASH - TURN SIGNAL FUNCTIONS NORMALLY Inspect ^ Blown fuse. ^ Inoperative hazard warning flasher. ^ Loose turn signal switch connection. ^ Damaged turn signal switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 11138 Turn Signal Switch: Service and Repair REMOVE OR DISCONNECT This lever includes the headlamp, headlamp dimmer, turn signal and hazard switches. It also includes the cruise control switch, if equipped. 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Upper and lower steering column covers. 4. Dampener assembly. 5. Switch assembly. INSTALL OR CONNECT 1. Switch assembly. 2. Dampener assembly. 3. Upper and lower steering column covers. 4. Tilt lever to column (if used). 5. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > S107 Vanity Lamp: Locations S107 In the engine harness, front left side of the engine, approximately 34cm (13 in) from the engine compartment fuse/relay center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > S107 > Page 11143 Vanity Lamp: Locations S203 In the dash harness, approximately 29 cm (11in) from the electronic brake control module connector C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > S107 > Page 11144 Vanity Lamp: Locations S206 In the dash harness, approximatley 21.5 cm (8.5 in) from P201, toward the instrument cluster connectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > S107 > Page 11145 Vanity Lamp: Locations S214 In the dash harness, approximatley 18 cm (7 in) from the electronic brake control modle connector C2. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > S107 > Page 11146 Vanity Lamp: Locations S277 In the dash harness, approximately 77.5 cm (30.5 in) from P201 toward the data link connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 Heated Glass Element: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11174 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11175 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11176 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11177 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11178 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11179 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11180 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11181 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11182 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11183 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11184 Heated Glass Element: Connector Views CONNECTOR VIEWS C1/C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11185 Rear Defogger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 11186 Heated Glass Element: Description and Operation With the Ignition Switch in the RUN position, voltage is applied to the Rear Defogger Control Switch. When the Rear Defogger Control Switch is pressed, voltage is applied to the solid state Timing Circuit, providing voltage to the ON Indicator and the rear Defogger. The rear window becomes warm to remove the condensation from the surface of the window.The contact in the Timing Circuit stays closed until the Rear Defogger Control Switch is pressed again, the timer cycle is complete, or the Ignition Switch is turned to the OFF position. The first time the Rear Defogger Control Switch is pressed, the Timing Circuit allows the Rear Defogger to operate for approximately ten minutes. Each time after that when the Rear Defogger Control Switch is pressed, the Timing Circuit operates for approximately five minutes. The Timing Circuit resets to ten minutes when the Ignition Switch is turned to the OFF position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures Heated Glass Element: Diagnostic Trouble Code Tests and Associated Procedures Circuit Operation With the Ignition Switch in the RUN position, voltage is applied to the Rear Defogger Control Switch. When the Rear Defogger Control Switch is pressed, voltage is applied to the solid state Timing Circuit, providing voltage to the ON Indicator and the rear Defogger. The rear window becomes warm to remove the condensation from the surface of the window.The contact in the Timing Circuit stays closed until the Rear Defogger Control Switch is pressed again, the timer cycle is complete, or the Ignition Switch is turned to the OFF position. The first time the Rear Defogger Control Switch is pressed, the Timing Circuit allows the Rear Defogger to operate for approximately ten minutes. Each time after that when the Rear Defogger Control Switch is pressed, the Timing Circuit operates for approximately five minutes. The Timing Circuit resets to ten minutes when the Ignition Switch is turned to the OFF position. Troubleshooting Hints 1. Check the RR Defog and the HVAC Fuses by visual inspection. 2. If one or more of the grid lines do not heat, refer to Stationary Windows for grid line repair procedures. See: Windows 3. If the Panel Light is inoperable with the Headlamp Switch in the PARK or HEAD positions, check the bulb and the wiring to bulb. Refer to Interior Lights Dimming. See: Lighting and Horns 4. If the Rear Defogger ON Indicator lights continuously or does not light at all, but Rear Defogger operates normally, replace the Heater-A/C and Rear Defogger Control Assembly. Refer to Heater-A/C Control. See: Heating and Air Conditioning 5. If the Rear Defogger does not stay on for the ten minute/five minute time periods, replace the Heater-A/C and Rear Defogger Control Assembly. Refer to Heater-A/C Control. 6. If the Rear Defogger does not turn off replace the Heater-A/C and Rear Defogger Control Assembly. Refer to Heater-A/C Control. ^ Check for a broken (or partially broken) wire inside of the insulation which could cause system failure but prove good in a continuity/voltage check. Refer to Troubleshooting Procedures. ^ Check for proper installation of aftermarket electronic equipment which may affect the integrity of other systems. Refer to Troubleshooting Procedures. See: Diagrams/Diagnostic Aids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 11189 Heated Glass Element: Symptom Related Diagnostic Procedures Rear Defogger Does Not Operate (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 11190 Rear Defogger Does Not Operate (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 11195 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 11201 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 11202 Power Window Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 11203 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR Power Window Switch: Diagrams LR LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 11206 LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 11207 Power Window Switch: Diagrams Master Window Switch Master Window Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 11208 Master Window Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 11209 Power Window Switch: Diagrams RR RR Window Switch RR Window Switch (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > LR > Page 11210 RR Window Switch (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch Power Window Switch: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. 6. Front door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11213 INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11214 Power Window Switch: Service and Repair Upper Extension Trim Panel Replacement Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11215 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11216 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11217 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11218 Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > LH Front Power Window Motor Connector Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > LH Front Power Window Motor Connector > Page 11224 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 11225 Power Window Motor: Diagrams LF Window Motor LR Window Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 11226 RF Window Motor RR Window Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 11227 Power Window Motor: Service and Repair For Window Regulator Motor service and repair, refer to Window Regulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 11232 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 11233 Power Window Switch: Connector Locations Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 11234 Component Location Views Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR Power Window Switch: Diagrams LR LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR > Page 11237 LR Window Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR > Page 11238 Power Window Switch: Diagrams Master Window Switch Master Window Switch (C2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR > Page 11239 Master Window Switch (C1) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR > Page 11240 Power Window Switch: Diagrams RR RR Window Switch RR Window Switch (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > LR > Page 11241 RR Window Switch (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch Power Window Switch: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. 6. Front door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11244 INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11245 Power Window Switch: Service and Repair Upper Extension Trim Panel Replacement Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11246 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11247 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11248 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11249 Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Back Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 11263 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 11264 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair WINDOW REGULATOR HANDLE REPLACEMENT REMOVAL PROCEDURE TOOLS REQUIRED J 9886-01 Regulator Handle Clip Remover 1. Place the door window regulator handle in the upward position. 2. Insert the J 9886-01 or an equivalent between the door window regulator handle and the door trim panel. 3. Push the J 9886-01 downward. 4. Remove the door window regulator handle (4). 5. Remove the door window regulator handle bearing plate. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair > Page 11272 1. Install the retaining clip to the door window regulator handle (4). 2. Install the door window regulator handle bearing plate. 3. Place the door window in the closed position. 4. Push the door window regulator handle (4) in order to secure the retaining clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch Window Regulator: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. 6. Front door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11277 INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11278 Window Regulator: Service and Repair Upper Extension Trim Panel Replacement Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11279 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11280 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11281 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11282 Window Regulator: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11283 Window Regulator: Service and Repair Window Regulator Handle Replacement WINDOW REGULATOR HANDLE REPLACEMENT REMOVAL PROCEDURE TOOLS REQUIRED J 9886-01 Regulator Handle Clip Remover 1. Place the door window regulator handle in the upward position. 2. Insert the J 9886-01 or an equivalent between the door window regulator handle and the door trim panel. 3. Push the J 9886-01 downward. 4. Remove the door window regulator handle (4). 5. Remove the door window regulator handle bearing plate. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11284 1. Install the retaining clip to the door window regulator handle (4). 2. Install the door window regulator handle bearing plate. 3. Place the door window in the closed position. 4. Push the door window regulator handle (4) in order to secure the retaining clip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11285 Window Regulator: Service and Repair Door Inside Handle and Power Door Lock Switch DOOR INSIDE HANDLE BEZEL AND POWER DOOR LOCK SWITCH Door Inside Handle Bezel And Power Door Lock Switch - Pontiac REMOVE OR DISCONNECT 1. Pull door inside handle to the full open position. 2. Press on inside handle bezel. 3. Pry door inside handle bezel from top using a flat blade tool. 4. Pull door inside bezel upward. 5. (Front Door Only) Door lock switch wire harness. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11286 6. Front door inside bezel. INSTALL OR CONNECT 1. (Front Door Only) Door lock switch wire harness. 2. Pull door inside handle to the full open position. 3. Insert front tab on door inside bezel to locating notch behind front edge of opening in door trim panel. 4. Push door inside bezel downward to insert lower tab behind lower edge of door trim panel. 5. Insert rear most lowest tab of door inside bezel to edge of door trim panel. 6. Snap into place the top two tabs on door inside bezel. Hardtop UPPER EXTENSION TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the finish screw that retains the bezel to the front door upper trim. 2. Remove the finish screw that retains the remote control mirror bezel to the front door upper trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11287 3. Remove the finish screw that retains the remote control power mirror bezel to the front door upper trim. 4. Disconnect the power mirror switch. (Power windows only). 5. Remove the upper trim finish panel from the front door. INSTALLATION PROCEDURE 1. Install the bezel to the front door upper trim finish panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11288 2. Install the remote control mirror bezel to the front door upper trim finish panel. 3. Connect the power mirror switch to the front door upper trim finish panel. (Power window only). 4. Install the front door upper trim finish panel to the remote control power mirror bezel. (Power window only). NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw to the front door upper trim finish panel. Tighten Tighten the screw to 1 Nm (12 lb in). Convertible UPPER EXTENSION TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11289 REMOVAL PROCEDURE 1. Remove the screw (5). 2. Remove the upper front panel (4). 3. Remove the mirror patch filler (3). INSTALLATION PROCEDURE 1. Install the mirror patch filler (3). 2. Install the upper front panel (4). NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screw (5). Tighten Tighten the screw to 1 Nm (12 lb in). Power Window Switch Replacement POWER WINDOW SWITCH (HARDTOP) REMOVAL PROCEDURE 1. Use a flat-bladed screwdriver in order to pry the power window switch outward. 2. Disconnect the power window switch wire harness. 3. Remove the power window switch. INSTALLATION PROCEDURE 1. Connect the power window switch wire harness. 2. Install the power window switch. Ensure the unit is retained. Window Regulator Handle Replacement WINDOW REGULATOR HANDLE REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11290 TOOLS REQUIRED J 9886-01 Regulator Handle Clip Remover 1. Place the door window regulator handle in the upward position. 2. Insert the J 9886-01 or an equivalent between the door window regulator handle and the door trim panel. 3. Push the J 9886-01 downward. 4. Remove the door window regulator handle (4). 5. Remove the door window regulator handle bearing plate. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11291 1. Install the retaining clip to the door window regulator handle (4). 2. Install the door window regulator handle bearing plate. 3. Place the door window in the closed position. 4. Push the door window regulator handle (4) in order to secure the retaining clip. Water Deflector Replacement WATER DEFLECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the door armrest hanger plate. 3. Pull the door water deflector from the door inner panel. INSTALLATION PROCEDURE NOTE: Proper sealing is necessary in order to prevent water entry into the door and possible damage to inner door components. 1. Apply the sealer to the original sealing areas on the water deflector. 2. Install the water deflector. 3. Install the armrest hanger plate. 4. Install the door trim panel. Door Trim Panel Replacement DOOR TRIM PANEL REPLACEMENT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11292 REMOVAL PROCEDURE TOOLS REQUIRED J 38778 Door Trim Pad Remover 1. Remove the inside handle bezel from the front door. 2. Remove the power door lock switch. 3. Remove the power window switch, if equipped. 4. Remove the window regulator handle, if equipped. 5. Remove the upper trim finish panel. 6. Remove the lower screws (3) from the front door trim panel. 7. Remove the screws (2) from the front door arm rest. 8. Using the J 38778, remove the front door trim panel fasteners from the front door inner panel (1). 9. Remove the front door trim panel (1). INSTALLATION PROCEDURE 1. Push the front door trim panel (1) inward to engage the fasteners. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the arm rest screws (2). Tighten Tighten the screws (2) to 1.5 Nm (13.3 lb in). 3. Install the lower screws (3) to the front door trim panel. Tighten Tighten the screws (3) to 1.5 Nm (13.3 lb in). 4. Install the upper trim finish panel. 5. Install the window regulator handle, if equipped. 6. Install the power window switch, if equipped. 7. Install the inside handle bezel. 8. Install the power door lock switch. Window Replacement DOOR WINDOW ASSEMBLY Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11293 Front Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11294 Rear Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11295 Door Window Assembly Sash REMOVE OR DISCONNECT 1. Door window assembly to the down position to align with access holes. 2. Door trim panel. 3. Enough door water deflector to access door window assembly nuts. 4. Door window assembly nuts. 5. Bolts and rear door energy absorber. 6. Lift rear of door window assembly, then front of door window assembly. 7. Door window assembly from outside of door. 8. Door window assembly sash rivet. 9. Door window assembly sash. INSTALL OR CONNECT 1. Door window assembly sash. 2. Door window assembly sash rivet. 3. Door window assembly from outside of door. 4. Door window assembly by inserting front of door window assembly, then rear of door window assembly. 5. Door window assembly nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 6. Rear door energy absorber and bolts. 7. Door water deflector. 8. Door trim panel. With Power Regulator WINDOW REGULATOR REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11296 1. Remove the door trim panel. 2. Remove the water deflector in order to access the window regulator. 3. Remove the window assembly. 4. Remove the power window regulator bolts (3). 5. Remove the power window regulator rivets (2). 6. Remove the power window regulator (5). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11297 1. Install the power window regulator (5). 2. Install the power window regulator rivets (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the power window regulator bolts (3). Tighten Tighten the bolts (3) to 10 Nm (89 lb in). 4. Install the power window regulator nuts (4). Tighten Tighten the nuts (4) to 10 Nm (89 lb in). 5. Install the window assembly. 6. Install the water deflector. 7. Install the door trim panel. With Manual Regulator WINDOW REGULATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector in order to access the window regulator. 3. Remove the window assembly. 4. Remove the manual window regulator bolts (3). 5. Remove the manual window regulator rivets (2). 6. Remove the manual window regulator (5). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11298 1. Install the manual window regulator (5). 2. Install the manual window regulator rivets (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator bolts (3). Tighten Tighten the bolts (3) to 10 Nm (89 lb in). 4. Install the manual window regulator nuts (4). Tighten Tighten the nuts (4) to 10 Nm (89 lb in). 5. Install the window assembly. 6. Install the water deflector. 7. Install the door trim panel. With Power Regulator WINDOW REGULATOR REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11299 1. Remove the door trim panel. 2. Remove the water deflector in order to access the window regulator. 3. Remove the window assembly. 4. Remove the power window regulator rivets (3). 5. Remove the power window regulator (1). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11300 1. Install the power window regulator (1). 2. Install the power window regulator rivets (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the power window regulator nuts (2). Tighten Tighten the nuts (2) to 10 Nm (89 lb in). 4. Install the window assembly. 5. Install the water deflector. 6. Install the door trim panel. With Manual Regulator WINDOW REGULATOR REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11301 1. Remove the door trim panel. 2. Remove the water deflector in order to access the window regulator. 3. Remove the window assembly. 4. Remove the manual window regulator rivets (3). 5. Remove the manual window regulator (1). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11302 1. Install the manual window regulator (1). 2. Install the manual window regulator rivets (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator nuts (2). Tighten Tighten the nuts (2) to 10 Nm (89 lb in). 4. Install the window assembly. 5. Install the water deflector. 6. Install the door trim panel. Convertible WINDOW REGULATOR REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11303 1. Remove the trim panel. 2. Remove the door trim panel. 3. Peel the water deflector away from the door inner panel as necessary. Refer to Water Deflector Replacement - Door. CAUTION: When it is necessary to operate the drivers side window during repairs, the power window may lock into the express down mode causing the window to lower fully without stopping even though the switch has been released. Failure to exercise caution around the regulator assembly when operating the switch may result in personal injury and/or regulator damage. 4. Loosen the nuts (3) in order to allow removal of the door glass from the regulator. Secure the door glass. 5. Remove the downstop bumper from the door frame. 6. Disconnect the window regulator wire connector (if equipped). CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11304 7. Punch out the center pins in order to remove the rivets (3). Drill out the rivets. 8. Remove the screws (2). 9. Remove the window regulator assembly (1) through the door inner panel access hole. 10. Glean any rivet debris from the bottom of the door. INSTALLATION PROCEDURE 1. Install the window regulator assembly (1) through the door inner panel access hole. 2. Add LOCTITE 242 or equivalent to the screw threads. 3. Install the screws (2). 4. Install the rivets (3) that attach the window regulator assembly (1) to the door inner panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Inside Handle and Power Door Lock Switch > Page 11305 5. Connect the power window regulator wire connector (if equipped). 6. Install the downstop bumper to the door frame. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the nuts (3) that attach the door window glass. Tighten Tighten the nuts (3) to 6 Nm (53 lb in). 8. Inspect the operation of the window regulator assembly. 9. Inspect for proper alignment of the door window glass. 10. Install the water deflector. 11. Install the trim panel. 12. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure Window Seal: Technical Service Bulletins Header Weatherstrip - Revised Replacement Procedure File In Section: 10 - Body Bulletin No.: 83-15-03 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-13 - Revised Remove and Install Procedure for Header Weatherstrip and Retainers Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for header weatherstrip and retainers, convertible only, in Section 10-13 of the Service Manual. Procedure Header Weatherstrip and Retainers Remove or Disconnect Important: Removing the weatherstrip retainers is not necessary if only the weatherstrip is to be serviced. 1. Unlatch and lower folding top. 2. Windshield garnish molding. Refer to Windshield Garnish Molding in this section. 3. Push-pin retainers securing the header weatherstrip at top of the LH and RH A-pillars. 4. Clips securing the header weatherstrip at bottom of the LH and RH A-pillars. 5. Header weatherstrip by pulling up while separating the adhesive bond with a flat bladed tool. 6. Screws securing A-pillar weatherstrip retainer. 7. Screws securing header weatherstrip retainer. 8. Header weatherstrip retainer. 9. Header garnish molding retainer. Clean ^ Adhesive from parts that will be reused ^ Foam tape from parts that will be reused ^ Foam tape from header surface ^ Butyl tape from header surface Inspect ^ Header weatherstrip for holes, rips or breaks in the surface skin. If holes, rips or breaks are found, the weatherstrip must be replaced. Install or Connect Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11310 1. 50.8 mm (2 in.) long x 12.7 mm (1/2 in.) wide x 1.6 mm (1/16 in.) thick butyl tape to header surface centered over both ditch moldings. See Figures 1 and 2. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11311 2. 1,524 mm (60 in.) long x 25.4 mm (1 in.) wide x 3.2 mm (1/8 in.) thick PVC closed-cell foam tape centered side-to-side to header surface. See Figure 3. 3. 1,524 mm (60 in.) long x 12.7 mm (1/2 in.) wide x 1.6 mm (1/16 in.) thick butyl tape running from top end of one A-pillar weatherstrip retainer, up and across the header, overlapping the ditch moldings butyl and to the top edge of the other A-pillar. Do not remove the protective backing from the butyl tape at this time. See Figure 4. 4. Header weatherstrip retainer to header. 5. Screws securing header weatherstrip retainer. 6. Windshield garnish molding. Refer to Windshield Garnish Molding in this section. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11312 7. Continuous 4.8 mm (3/16 in.) diameter bead of pumpable butyl inside header weatherstrip retainer, out and down to both A-pillar weatherstrip retainers. See Figure 5. 8. Lay front header weatherstrip in position to the header retainer. 9. Push-pin retainers to secure LH and RH ends of weatherstrip to header corners. 10. Using a plastic trim stick or wheel-type installation tool, install the front of weatherstrip into the retainer. 11. Bottom clips of weatherstrip at the A-pillar. 12. Remove protective backing from the butyl tape. 13. Smooth out weatherstrip in the header retainer to work out any wrinkles along header and at the A-pillars. Ensure the A-pillar corners of weatherstrip do not excessively roll downward. Otherwise, the door glass, when closed, will pull seal downward more. 14. Pumpable butyl at LH and RH bottom ends of the A-pillar part of the weatherstrip. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11313 15. A-pillar part of the weatherstrip to weatherstrip retainer, using a plastic trim stick. 16. Weatherstrip all along the butyl strip. 17. Close convertible top and fully raise the door windows. Ensure the door window to A-pillar corner seal is a proper fit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11322 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11332 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11341 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit Windshield: All Technical Service Bulletins New Windshield/Glass Urethane Adhesive Caulking Kit File In Section: 10 - Body Bulletin No.: 83-15-16 Date: October, 1998 INFORMATION Subject: New Windshield and Stationary Glass Urethane Adhesive Caulking Kit Models: 1990-99 All Passenger Cars and Trucks As a result of a change from standard viscosity urethane to high-viscosity urethane, a new Urethane Adhesive Caulking Kit, P/N 12346392, is now available from GMSPO. This kit contains the "High Viscosity" Urethane Adhesive for thicker and more consistent bead size applications. When applied properly, this new high viscosity urethane in many instances will eliminate the need for depth setting blocks or the damming material to control squeeze out. The following is the contents of the new kit: Like the standard viscosity urethane contained in kit (P/N 12346284) that it replaces, it is a one-part, moisture cure product with curing times that vary as a result of changes in either temperature or humidity. THE REQUIRED TIME FOR THIS NEW ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer, IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. Alternate equivalent materials for this kit may be available from a local glass repair shop under the following product numbers: Other manufacturers of Urethane Adhesive that have documented their ability to meet or exceed General Motors specification # 3651M (Performance Requirements for Stationary Glass Bonding Adhesive System Service) are also considered to be equivalent to GM Kit (P/N 12346392). In previously published Corporate Bulletin Number 73-10-54, increasing customer demands for faster service have resulted in quicker two-part urethane adhesives to be made available. Essex Beta Seal U216* (two-part urethane adhesive) also meets the General Motors 3651M Specification and can be Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit > Page 11350 used when the customer demands quicker repair of the vehicle than the above described one-part product can provide. This two-part, chemical cure product requires ONE (1) TO ONE-AND-ONE-HALF (1-1/2) HOURS FOR CURING BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This two-part product also requires primers on the glass and pinchweld surfaces. The primers and applicator daubers are not included with this two-part product and therefore, must be purchased separately. In addition, this two-part product requires a special applicator (gun) for proper mixing and dispensing of the adhesive. Important: The U216 product is NOT available from GMSPO and must be obtained locally. * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such products which may be available from other sources. When using either of the above described products, make sure to follow the manufacturer's directions for application and drying times. For information regarding the removal and installation of stationary glass, consult the appropriate Service Manual. Parts information P/N Description 12346392 Urethane Adhesive Caulking Kit Parts are expected to be available from GMSPO, 10/12/98. Important: The previously recommended adhesive kit (P/N 12346284) will no longer be available from GMSPO once inventory is exhausted. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 72-05-04 > Aug > 97 > Warranty - Guidelines for Claiming Windshield Replace Windshield: All Technical Service Bulletins Warranty - Guidelines for Claiming Windshield Replace File In Section: Warranty Administration Bulletin No.: 72-05-04 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Claiming C0034 - Windshield Replacement Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with guidelines for using the above subject labor operations. In an effort to understand the windshield replacements, the following two phase approval process is being implemented. We feel this approach will allow GM to be responsive to repair decisions on vehicles over 10,000 miles (16,000KMS), while providing you, our dealers, the empowerment to address customer needs on those cases requiring repairs early in the vehicle's life, under 10,000 miles (16,000KMS). Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Windshield replacement on vehicles under 10,000 miles (16,0OOKMS) can only be made after Service Management inspection, review and approval. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. ^ Windshield replacement on vehicles over 10,000 miles (16,000KMS) can only be made after Service Management inspection, review and approval from the divisional service representative. Vehicles may be required to be held for wholesale inspection. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. The claim will require wholesale authorization for payment. Additional Requirements ^ Windshields replaced must be held for the normal parts retention period and the defect should be clearly identified on the glass by means of tape and/or a grease pencil. ^ Sublet windshield replacements, like other sublet repairs are to be claimed for actual dealership cost less any discounts and or allowances offered. Sublet repairs cannot exceed the normal allowance provided to the dealership had the repair been completed in-house. See your GM Policy and Procedure Manual for the complete guidelines. Windshields damaged by normal wear, road hazards, vandalism, or other physical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11360 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit Windshield: All Technical Service Bulletins New Windshield/Glass Urethane Adhesive Caulking Kit File In Section: 10 - Body Bulletin No.: 83-15-16 Date: October, 1998 INFORMATION Subject: New Windshield and Stationary Glass Urethane Adhesive Caulking Kit Models: 1990-99 All Passenger Cars and Trucks As a result of a change from standard viscosity urethane to high-viscosity urethane, a new Urethane Adhesive Caulking Kit, P/N 12346392, is now available from GMSPO. This kit contains the "High Viscosity" Urethane Adhesive for thicker and more consistent bead size applications. When applied properly, this new high viscosity urethane in many instances will eliminate the need for depth setting blocks or the damming material to control squeeze out. The following is the contents of the new kit: Like the standard viscosity urethane contained in kit (P/N 12346284) that it replaces, it is a one-part, moisture cure product with curing times that vary as a result of changes in either temperature or humidity. THE REQUIRED TIME FOR THIS NEW ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer, IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. Alternate equivalent materials for this kit may be available from a local glass repair shop under the following product numbers: Other manufacturers of Urethane Adhesive that have documented their ability to meet or exceed General Motors specification # 3651M (Performance Requirements for Stationary Glass Bonding Adhesive System Service) are also considered to be equivalent to GM Kit (P/N 12346392). In previously published Corporate Bulletin Number 73-10-54, increasing customer demands for faster service have resulted in quicker two-part urethane adhesives to be made available. Essex Beta Seal U216* (two-part urethane adhesive) also meets the General Motors 3651M Specification and can be Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit > Page 11369 used when the customer demands quicker repair of the vehicle than the above described one-part product can provide. This two-part, chemical cure product requires ONE (1) TO ONE-AND-ONE-HALF (1-1/2) HOURS FOR CURING BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This two-part product also requires primers on the glass and pinchweld surfaces. The primers and applicator daubers are not included with this two-part product and therefore, must be purchased separately. In addition, this two-part product requires a special applicator (gun) for proper mixing and dispensing of the adhesive. Important: The U216 product is NOT available from GMSPO and must be obtained locally. * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such products which may be available from other sources. When using either of the above described products, make sure to follow the manufacturer's directions for application and drying times. For information regarding the removal and installation of stationary glass, consult the appropriate Service Manual. Parts information P/N Description 12346392 Urethane Adhesive Caulking Kit Parts are expected to be available from GMSPO, 10/12/98. Important: The previously recommended adhesive kit (P/N 12346284) will no longer be available from GMSPO once inventory is exhausted. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 72-05-04 > Aug > 97 > Warranty - Guidelines for Claiming Windshield Replace Windshield: All Technical Service Bulletins Warranty - Guidelines for Claiming Windshield Replace File In Section: Warranty Administration Bulletin No.: 72-05-04 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Claiming C0034 - Windshield Replacement Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with guidelines for using the above subject labor operations. In an effort to understand the windshield replacements, the following two phase approval process is being implemented. We feel this approach will allow GM to be responsive to repair decisions on vehicles over 10,000 miles (16,000KMS), while providing you, our dealers, the empowerment to address customer needs on those cases requiring repairs early in the vehicle's life, under 10,000 miles (16,000KMS). Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Windshield replacement on vehicles under 10,000 miles (16,0OOKMS) can only be made after Service Management inspection, review and approval. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. ^ Windshield replacement on vehicles over 10,000 miles (16,000KMS) can only be made after Service Management inspection, review and approval from the divisional service representative. Vehicles may be required to be held for wholesale inspection. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. The claim will require wholesale authorization for payment. Additional Requirements ^ Windshields replaced must be held for the normal parts retention period and the defect should be clearly identified on the glass by means of tape and/or a grease pencil. ^ Sublet windshield replacements, like other sublet repairs are to be claimed for actual dealership cost less any discounts and or allowances offered. Sublet repairs cannot exceed the normal allowance provided to the dealership had the repair been completed in-house. See your GM Policy and Procedure Manual for the complete guidelines. Windshields damaged by normal wear, road hazards, vandalism, or other physical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Reservoir > Component Information > Service and Repair Headlamp Washer Reservoir: Service and Repair REMOVAL PROCEDURE 1. Remove the lid completely from the washer solvent container. 2. Raise the vehicle. 3. Remove the LF wheel. 4. Remove the left front headlight. 5. Remove the splash shield. 6. Disconnect the electrical connector from the washer pump. 7. Disconnect the hose from the washer pump. 8. Remove the three screws, the washer solvent container and the air induction assembly from the vehicle. 9. Remove the two retainers and the air induction assembly from the washer solvent container. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Reservoir > Component Information > Service and Repair > Page 11378 1. Install the air induction assembly and the two retainers onto the washer solvent container. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the washer solvent container and the air induction assembly with the three screws. Tighten Tighten the screws to 10 N.m (88 lb in). 3. Connect the hose to the washer pump. 4. Connect the electrical connector to the washer pump. 5. Install the splash shield. 6. Install the left front headlight. 7. Install the LF wheel. 8. Lower the vehicle. 9. Install the lid on the container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Specifications Wiper Control Module: Specifications Wiper Drive System Module to Vehicle Screws ..........................................................................................................................................10 N.m (88 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the right side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11387 Wiper Switch Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11388 Wiper Switch: Service and Repair REMOVE OR DISCONNECT 1. Inflator module and steering wheel. 2. Tilt lever from column (if used). NOTICE: If necessary, use locking pliers with a piece of rubber (such as a spark plug boot) between the jaws to aid in preventing damage to the tilt lever during removal. 3. Remove upper and lower steering column covers. 4. Dampener assembly. 5. Headlight switch assembly. 6. Windshield wiper switch assembly. INSTALL OR CONNECT 1. Windshield wiper switch assembly. 2. Upper and lower steering column covers. 3. Tilt lever to column (if used). 4. Inflator module and steering wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Location View At the left front of the engine compartment, forward of the wheel splash shield Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11392 Washer Pump Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11393 Windshield Washer Pump: Service and Repair REMOVAL PROCEDURE 1. Disconnect the electrical connector from the washer pump. 2. Disconnect the hose from the washer pump. 3. Remove the washer pump from the washer solvent container. INSTALLATION PROCEDURE 1. Install the washer pump in the washer solvent container. 1.1. Push the washer pump down into the washer solvent container completely. 1.2. Push the top of the washer pump into the side of the washer solvent container. 2. Connect the hose to the washer pump. 3. Connect the electrical connector to the washer pump. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications Wiper Arm to Shaft Nut ........................................................................................................................ ........................................................30 N.m (22 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11397 Wiper Arm: Testing and Inspection Wiper Arm Tip Pressure Check 1. Run the wiper arms to the mid-wipe position. 2. Remove the wiper blades from the wiper arms. 3. Attach a scale to the end of the wiper arm and measure the force required to lift the wiper arm perpendicular to the windshield to normal working height (height with the blade attached). 4. Replace the wiper arm if the measurement is not within the specification. Tip Pressure Driver side - 8.1-9.5 Newtons (26-31 oz) Passenger side - 5.8-7.0 Newtons (19-25 oz) 5. Install the wiper blades on the wiper arms. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11398 Wiper Arm: Service and Repair REMOVAL PROCEDURE 1. Place the wiper arms in the park position. 2. Open the hood. 3. Install a protective covering over the fenders. 4. Remove the washer hose from the washer nozzle. 5. Remove the cover from the nut. 6. Remove the nut from the wiper arm and the wiper transmission drive shaft. IMPORTANT: Use a battery terminal puller to remove the wiper arms if they cannot be removed by rocking. 7. Remove the wiper arm from the wiper transmission drive shaft by rocking. INSTALLATION PROCEDURE IMPORTANT: Hold the measuring device at 90 degrees (perpendicular) to the wiper blade. 1. Install the wiper arm onto the wiper transmission drive shaft while maintaining a distance of 45 mm (1.77 in) between the wiper blade and the bottom of the windshield. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the nut onto the wiper transmission drive shaft and the wiper arm. Tighten Tighten the nut to 30 N.m (22 lb ft). 3. Place the cover on the nut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11399 IMPORTANT: Lubricate the washer hose with windshield washer solvent in order to ease installation onto the washer nozzle. 4. Connect the washer hose to the washer nozzle. 5. Remove the protective covering from the fenders. 6. Close the hood. 7. Operate the wipers and inspect for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 11404 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 11405 Wiper Blade: Testing and Inspection Blade Element Check 1. Remove the wiper blades from the wiper arms. 2. Look down the length of the blade element. 3. Replace the wiper blade if the rubber element which contacts the glass is not on the centerline of the blade ± 5 degrees. 4. Install the wiper blades on the wiper arms. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Assembly Replacement Wiper Blade: Service and Repair Wiper Blade Assembly Replacement REMOVAL PROCEDURE 1. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 2. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Assembly Replacement > Page 11408 Wiper Blade: Service and Repair Wiper Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with water. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Specifications Wiper Control Module: Specifications Wiper Drive System Module to Vehicle Screws ..........................................................................................................................................10 N.m (88 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Wiper Motor Mounting Screws ............................................................................................................ ........................................................10 N.m (88 lb in) Wiper Motor Cover Screws2 N.m (18 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11415 Wiper Motor: Locations At the left rear of the engine compartment, in front of the dash Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11416 Wiper Motor Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor REMOVAL PROCEDURE TOOLS REQUIRED J 39232 Wiper Transmission Separator 1. Remove the wiper arms. 2. Remove the plenum chamber water deflector. 3. Remove the electrical connector from the wiper motor. 4. Remove the three screws and the wiper drive system module from the vehicle. 5. Remove the wiper transmission from the wiper motor crank arm using the J39232. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11419 6. Remove the two screws and the wiper motor from the tube frame. INSTALLATION PROCEDURE TOOLS REQUIRED J 39529 Wiper Transmission Installer NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the wiper motor onto the tube frame with the two screws. Tighten Tighten the screws to 10 N.m (88 lb in). 2. Install the wiper transmission onto the wiper motor crank arm using the J 39529. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11420 3. Install the wiper drive system module onto the vehicle with the three screws. Tighten Tighten the screws to 10 N.m (88 lb in). 4. Connect the electrical connector onto the wiper motor. 5. Install the plenum chamber water deflector. 6. Install the wiper arms. 7. Operate the wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11421 Wiper Motor: Service and Repair Wiper Motor Cover Replacement REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the plenum chamber water deflector. 3. Remove the three screws and the wiper motor cover from the wiper motor. 4. Disconnect the electrical connector from the wiper motor. INSTALLATION PROCEDURE NOTE: Reter to Fastener Notice in Cautions and Notices. 1. Install the wiper motor cover onto the wiper motor with the three screws. Tighten Tighten the three screws to 2 N.m (18 lb in). 2. Install the plenum chamber water deflector. 3. Install the wiper arms. 4. Operate the wipers and inspect for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Wiper Transmission to Tube Frame Screws ...................................................................................................................................................9 N.m (79 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications Wiper Pivot: Specifications Wiper Arm to Shaft Nut ........................................................................................................................ ........................................................30 N.m (22 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Windshield Wiper, Passlock (TM), Turn/Hazard, Cruise Control And Headlamp Connectors At the right side of the steering column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN 4 (1998)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11431 Wiper Switch Assembly